Download Print this page

SSANGYONG Rexton 2004 Service Manual

Chassis

page of 1306

/ 1306
Contents
Table of Contents
Bookmarks

Table of Contents

Advertisement

Quick Links

CHASSIS

SERVICE MANUAL

PYUNGTAEK, KOREA

Table of Contents

Advertisement

Chapters

Table of Contents

Need help?

Need help?

Do you have a question about the Rexton 2004 and is the answer not in the manual?

Questions and answers

Summary of Contents for SSANGYONG Rexton 2004

Page 1 CHASSIS SERVICE MANUAL PYUNGTAEK, KOREA...
Page 2 ELECTRIC SYSTEM The right is reserved to make changes at any time without notice. HVAC SYSTEM BODY RESTRAINT SYSTEM SSANGYONG MOTOR CO., LTD. PYUNGTAEK, KOREA...
Page 3 CHASSIS CONTENTS DRIVING SYSTEM......SECTION 03 AXLE & PROPELLER SHAFT ..SECTION 04 WHEEL & SHAFT ......SECTION 05 STEERING SYSTEM ....... SECTION 06 SUSPENSION SYSTEM....SECTION 07 BRAKE SYSTEM ......SECTION 08 ELECTRIC SYSTEM......SECTION 09 HVAC SYSTEM ........ SECTION 10 BODY..........
Page 4 SECTION DRIVING SYSTEM CONTENTS DC 5-SPEED AUTOMATIC TRANSMISSION..... 3A1 BTRA 4 AUTO TRANSMISSION......... 3A2 TSM54/52 MANUAL TRANSMISSION ......3B CLUTCH ................. 3C PART TIME..............3D TOD ................3E...
Page 5 3A1-1 SECTION 3A1 ´Ü¿ø 00 DC 5-SPEED AUTOMATIC TRANSMISSION Table of Contents GENERAL INFORMATION ....3A1-3 TROUBLE CODE AND DIAGNOSIS .. 3A1-52 Overview .......... 3A1-3 Trouble diagnosis with scanner ..3A1-52 Characteristics ......... 3A1-4 HYDRAULIC SYSTEM ....... 3A1-61 Structure .......... 3A1-5 Structure of valve body ....
Page 6 3A1-3 GENERAL INFORMATION OVERVIEW 34: D27DT (2WD) DC Part Number 61: D27DT (4WD) Engine Code DC Variant Number 62: E3.2 Engine (4WD) Number Serial Number Transmission Type Automatic Transmission for Automatic Transmission Assembly Passenger Car Y220_3A1001 DC 5-Speed Automatic Transmission DCAG 5-speed automatic transmission is an electronically controlled 5-speed transmission with a lockup clutch in the torque converter.
Page 7 3A1-4 CHARACTERISTICS Characteristic Function and Description Effect Slope recognition Recognize it according to engine RPM and accelerator Delay up shift (down hill, up hill) pedal position Engine torque limitation During 1st gear driving or reverse driving with full throttle Prevent automatic transmis- condition sion from overheating Engine torque decrease...
Page 8 3A1-5 STRUCTURE Basic structure of DC 5-speed automatic transmission Y220_3A1002 1. Torque converter 7. Disc brake B3 13. Freewheel F2 2. Oil pump 8. Disc clutch C3 14. Center planetary gear set 3. Input shaft 9. Disc brake B2 15. Electric control unit (valve body) 4.
Page 9 3A1-6 PERFORMANCE CURVE AND GENERAL CHARACTERISTICS Standard mode Lockup mode (open/sleeping) 5th gear open 5th gear sleeping 4th gear open 4th gear sleeping 3rd gear sleeping 3rd gear open Pedal value (%) 4-LOW mode Pedal value (%) Y220_3A1003 Pedal value (%) Note Y220_3A1004 1.
Page 10 3A1-7 SPECIFICATIONS Item W5A330 (300) W5A580 (400) Input torque 580 Nm 330 Nm Weight (including ATF) 78 kg 78 kg Diameter (Torque converter) 270 mm 270 mm Lockup function Gear ratios 3.951 3.595 2.423 2.186 1.405 1.486 1.000 1.000 0.831 0.833 Reverse: S mode / W mode 3.147/1.93...
Page 11 3A1-8 Item W5A330 (300) W5A580 (400) Mode switch W (Winter) S (Standard) One-way clutch F1, F2 Planetary gear set Plain planetary gear: 3 (number of pinion) 3, 4, 3 4, 4, 4 Disc clutch Disc: C1, C3 Single, Double Disc: C2 Only Double Disc brake Disc: B1...
Page 12 3A1-9 POWER FLOW Sectional View Y220_3A1005 Shifting elements Gear 1) Selector program switch: “S” mode 2) Selector program switch: “W” mode 3) Overrun DC 5-SPEED AUTOMATIC TRANSMISSION CHANGED BY REXTON SM - 2004.4 EFFECTIVE DATE AFFECTED VIN...
Page 13 3A1-10 1st Gear (3.932) Input Output 16. Torque converter lockup clutch E. 3rd gear ratio M. Center planetary gear set A. Engine speed F. Mounting elements P. Impeller B. Transmission, input shaft H. Rear planetary gear set T. Turbine wheel C.
Page 14 3A1-11 2nd Gear (2.408) Output 16. Torque converter lockup clutch D. 2nd gear ratio M. Center planetary gear set A. Engine speed E. Mounting elements P. Impeller B. Transmission, input shaft H. Rear planetary gear set T. Turbine wheel C. 1st gear ratio L.
Page 15 3A1-12 3rd Gear (1.486) Input Output 16. Torque converter lockup clutch D. Mounting elements P. Impeller A. Engine speed H. Rear planetary gear set T. Turbine wheel B. Transmission, input shaft L. Stator V. Front planetary gear set C. 1st gear ratio M.
Page 16 3A1-13 4th Gear (1.000) Output 16. Torque converter lockup clutch L. Stator T. Turbine wheel A. Engine speed M. Center planetary gear set V. Front planetary gear set B. Planetary gear set P. Impeller Y220_3A1009 * Input shaft: Clockwise rotation * Front ring gear: Clockwise rotation * Center ring gear and rear planetary gear carrier: Clockwise rotation * Front sun gear and planetary gear carrier: Clockwise rotation (direct connection)
Page 17 3A1-14 5th Gear (0.830) Output 16. Torque converter lockup clutch E. 3rd gear ratio M. Center planetary gear set A. Engine speed F. Mounting elements P. Impeller B. Transmission, input shaft H. Rear planetary gear set T. Turbine wheel C. 1st gear ratio L.
Page 18 3A1-15 Reverse 1st Gear (3.160, “S” Mode) Input Output 16. Torque converter lockup clutch E. Mounting elements M. Center planetary gear set A. Engine speed F. Mounting elements P. Impeller B. Transmission, input shaft H. Rear planetary gear set T. Turbine wheel C.
Page 19 3A1-16 Reverse 2nd Gear (1.930, “W” Mode) Input Output 16. Torque converter lockup clutch D. 2nd gear ratio M. Center planetary gear set A. Engine speed E. Mounting elements P. Impeller B. Transmission, input shaft H. Rear planetary gear set T.
Page 20 3A1-17 FUNCTION AND DESCRIPTION SELECTOR LEVER Y220_3A1013 P: Parking and starting position 4: Up shifting only up to 4th gear This position is used when the vehicle is parking, starting In general, up to 4th gear is automatically shifted at the nor- the engine or stationing the vehicle.
Page 21 3A1-18 TORQUE CONVERTER Function (4WD) Y220_3A1014 Torque converter is installed between engine and automatic transmission. It consists of pump impeller, turbine and stator. The pump impeller is welded at converter housing and the converter housing is bolted at fly wheel. The torque converter converts the mechanical energy from engine to hydraulic energy, and the turbine connected to transmission input shaft converts this hydraulic energy to mechanical energy again.
Page 22 3A1-19 Installation and Inspection • Place the automatic transmission upright as shown in figure and install the torque converter by rotating the torque converter. When installing from sideway, the torque converter sealing ring may be damaged by driving flange which could cause oil leaks. Y220_3A1015 •...
Page 23 3A1-20 LOCKUP CLUTCH Y220_3A1018 1. Impeller wheel 10. Multiple disc clutch pack 2. Turbine wheel 11. Piston 3. Stator wheel 4. Stator shaft A : Closed (lockup clutch activates) 5. Multiple disc clutch drum B : Slipping 6. Multiple disc clutch hub C : Open (lockup clutch deactivates) 7.
Page 24 3A1-21 Lockup Clutch Regulating Valve Torque converter Torque converter Transmission Lockup clutch output input lubrication points Torque converter lockup solenoid valve Oil sump drain Oil cooler Working pressure Oil sump drain Lubrication pressure Shift valve pressure Oil sump drain Y220_3A1019 Lockup clutch regulating valve controls the lockup clutch in torque converter and distributes the lubricating oil to the friction parts.
Page 25 3A1-22 PLANETARY GEAR SET Ring gear Pinion gear Sun gear Planetary gear carrier Input Output Locked Input Locked Output Output Relatively high Relatively low Direction reversal and step-down ratio step-down ratio step-down ratio Y220_3A1020 Relatively high step-down ratio Ring gear locked Sun gear driving (clockwise) Planet gears driven (rotating counterclockwise) Planet carrier driven (revolving clockwise)
Page 26 3A1-23 MULTIPLE-DISC CLUTCH Y220_3A1021 C1c. Internally toothed disc carrier C1 M1. Middle sun gear 1. Input shaft C2a. Piston C2 M3. Middle planet carrier 9. Externally toothed disc C2b. Externally toothed disc carrier C2 M4. Middle ring gear 10. Internally toothed disc C3a.
Page 27 3A1-24 FREEWHEEL Y220_3A1022 1. Outer race A. Rotation direction “A” 2. Inner race B. Rotation direction “B” 3. Locking elements V1/H1. Front or rear sun gear 4. Locking element cage Location Freewheels are installed in the front planetary gear set between the sun gear and the stator shaft, and in the rear planetary gear set between the sun gear and the intermediate shaft.
Page 28 3A1-25 SENSORS AND CONTROLS Components Valve body assembly Y220_3A1023 1. Cap 5. Lockup PWM solenoid valve 9. 1-2/4-5 shift solenoid valve 2. Socket bolt (M6 x 32) 6. 2-3 shift solenoid valve 10. 3-4 shift solenoid valve 3. Socket bolt (M6 x 30) 7.
Page 29 3A1-26 Shift Pressure Control Solenoid Valve Y220_3A1024 1. Leaf spring 7. Solenoid valve 2. Contact spring A. 1-2, 4-5 shift solenoid valve 3. Conductor track B. 3-4 shift solenoid valve 4. O-ring 8. Solenoid valve 5. O-ring C. Shift pressure control solenoid valve 6.
Page 30 3A1-27 Characteristics of up/downshift solenoid valve The solenoid valve remains energized and therefore open until I (Current) the shift process is completed according to the engine and transmission conditions. If a solenoid valve is energized, it opens and transmits shift valve pressure to the corresponding 2.5A command valve.
Page 31 3A1-28 Modulating Pressure (MP) and Shift Pressure (SP) Control Solenoid Valve Solenoid valve Y220_3A1027 1. Leaf spring 4. MP control solenoid valve 2. Shift plate 5. SP control solenoid valve 3. Strainer Function These valves control the modulating pressure and the shift Working Current 0 ~ 1.0 A pressure by applying appropriate electric current to sole-...
Page 32 3A1-29 Circuit diagram Y220_3A1029 DC 5-SPEED AUTOMATIC TRANSMISSION CHANGED BY REXTON SM - 2004.4 EFFECTIVE DATE AFFECTED VIN...
Page 33 3A1-30 Lockup Solenoid Valve Y220_3A1030 1. Leaf spring 3. Shift plate 2. O-ring Function This valve activates and releases the lockup clutch by Working Current 1.5 ~ 2.0 A adjusting the current to solenoid valve according to engine Operating distance 0.2 mm throttle opening value and output shaft speed.
Page 34 3A1-31 RPM Sensor sensor (n3) sensor (n2) Y220_3A1033 1. Leaf spring 3. Pulse ring 2. Valve body Function The RPM sensors are fixed to the shell of the hydraulic control unit via the contact tabs. A leaf spring, which rests against the valve body, presses the RPM sensors against the transmission housing.
Page 35 3A1-32 Circuit diagram sensor sensor Y220_3A1034 DC 5-SPEED AUTOMATIC TRANSMISSION CHANGED BY EFFECTIVE DATE REXTON SM - 2004.4 AFFECTED VIN...
Page 36 3A1-33 Oil Temperature Sensor Oil temperature sensor Y220_3A1035 Function The oil temperature sensor is installed in hydraulic control unit and is connected in series with the starter lock-out contact. This means that the temperature signal is transferred to TCU when the starter lock-out contact is closed. The oil temperature has a considerable effect on the shifting time and therefore the shift quality.
Page 37 3A1-34 Starter Lock-out Contact Y220_3A1037 1. Plunger 3. Reed contact 2. Permanent magnet Function The starter lock-out contact is installed beside oil temperature sensor and is actuated by a cam rail, which is located on the latching plate. In the selector lever positions “P” and “N”, the permanent magnet is moved away from the reed contact. This opens the reed contact and the transmission control module receives an electrical signal.
Page 38 3A1-35 Kick-down Control Y220_3A1039 Function When the throttle valve is partially opened, the shifting point gets faster. When the throttle valve is widely opened, shifting point is delayed because the system needs low speed gear with bigger driving force. Kick-down control is a system that enables to get bigger driving force as the down shift occurs by suddenly increasing the throttle openings during constant driving.
Page 39 3A1-36 Mode Switch Function The mode switch is installed beside the selector lever and it has two modes of “S” mode (Standard Mode) and “W” mode (Winter Mode). - “S” mode is used in normal driving (starts off with 1st gear). TCU (Transmission Control Unit) provides pleasant driving by changing the shifting pattern according to the driving habits (downhill gripping: approx.
Page 40 3A1-37 Reverse/Parking (R/P) Lock System Y220_3A1043 1. Selector lever 7. Locking lever 2. Shift pattern display 8. Shift detene spring 3. Parking lock release flap 9. Potentiometer for detecting selector lever position 4. Selector lever control unit 10. Base body 5.
Page 41 3A1-38 Circuit diagram Brake switch Selector lever control unit Y220_3A1044 Function of reverse (R) lock Above a speed of approx. 10 km/h, the R/P locking solenoid is actuated by the selector lever control unit. The R/P lock lever (8) is turned to the lock position. The tab on lock lever (10) locks the locking disc (1).
Page 42 3A1-39 Function of parking (P) lock The selector lever position “P” is locked whenever the R/P locking solenoid is not actuated by selector lever control unit. The prerequisites for this are as follows: * No voltage supply to the selector lever control unit (Ignition switch is not positioned to “ON”) * Brake pedal not depressed Under these conditions, the locking lever (8) is in the locking...
Page 43 3A1-40 Selector Lever Control Unit Function Selector lever control unit functions as follows: A. Informing the selector lever’s position to other units via CAN. B. Turning on the selector lever indicator while tail lamp is turning on. C. Turning on the back-up lamp during reverse driving. D.
Page 44 3A1-41 Circuit diagram Ignition switch Ignition switch Tail lamp relay Self diagnostic 10 Brake switch Selector lever control unit Backup lamp Instrument panel, HECU, ECU Y220_3A1049 DC 5-SPEED AUTOMATIC TRANSMISSION CHANGED BY REXTON SM - 2004.4 EFFECTIVE DATE AFFECTED VIN...
Page 45 3A1-42 CAN (Controller Area Network ) Function CAN input signal CAN output signal Selected gear Accelerator pedal position Shifted status Wheel speed (all wheels) Lock-up clutch status Engine rpm, Engine torque Automatic transmission Coolant temperature Kick-down status Downshift Driving conditions Speed control (constant) Engine torque control Meshed gear...
Page 46 3A1-43 TCU (Transmission Control Unit) Y220_3A1051 Function TCU controls the gear groups according to the driving conditions. It receives the driving data from many sensors and switches as input signals. It is also connected with ECU, HECU, instrument panel and selector lever control unit. 1.
Page 47 3A1-44 TCU block diagram Engine torque M/P S/V Max. Engine torque S/P S/V Engine power loss Engine rpm Power supply (valves) Engine Sol. ACC pedal position 1-2/4-5 gears S/V control valve Shift pattern changes 3-4 gears S/V Engine control status 2-3 gears S/V Engine torque Lockup clutch S/V...
Page 48 3A1-45 Characteristics of TCU and Automatic Transmission (Emergency Driving Mode) The emergency driving mode is to minimize vehicle’s operation when is a mode for maintaining minimum driving condi- tion when the automatic transmission is defective. In emergency driving mode, excessively long driving and unreason- able driving should be avoided to prevent bigger fault occurring in advance.
Page 49 3A1-46 Connector arrangement and pin functions Connector Y220_3A1053 Pin No. Description Connected to Diagnostic Diagnostic connector pin No.11 Initiating the starter relay Starter relay RPM sensor N2 13-pin plug No.3 RPM sensor voltage supply 13-pin plug No.7 1-2, 4-5 solenoid valve 13-pin plug No.13 3-4 solenoid valve 13-pin plug No.9...
Page 50 3A1-47 OTHER FUNCTIONS Oil Level Control Function This is the function that closes the opening between oil chamber and planetary gear set chamber, so that the gear set does not splash in oil if the oil level rises. The lubricating oil flowing continuously out of the gear sets returns through the opening (2) into the oil chamber. If the oil level rises, the oil forces the float (1) against the housing.
Page 51 3A1-48 Oil Check and Specification Lock pin Lock pin Y220_3A1055 Checking and adding Tip Automatic transmission fluid capacity and specification A. Place the vehicle on level ground. Pull out the lock pin and remove the cap (add 4 to 5 liter if oil has Fluid capacity Approx.
Page 52 3A1-49 Shift Rod Adjustment Adjustment Y220_3A1056 1. Range lever D. “D” range 2. Shift rod P. “P” range 3. Selector lever A. Disengage the shift rod from range lever and place the range lever at “D” position. B. Place the selector lever at “D” position. C.
Page 53 3A1-50 CIRCUIT DIAGRAM Starter, Selector Lever, CAN Communication Y220_3A1057 DC 5-SPEED AUTOMATIC TRANSMISSION CHANGED BY EFFECTIVE DATE REXTON SM - 2004.4 AFFECTED VIN...
Page 54 3A1-51 Solenoid, Oil Temperature Sensor, RPM Sensor (N2, N3) Y220_3A1058 DC 5-SPEED AUTOMATIC TRANSMISSION CHANGED BY REXTON SM - 2004.4 EFFECTIVE DATE AFFECTED VIN...
Page 55 3A1-52 TROUBLE CODE AND DIAGNOSIS TROUBLE DIAGNOSIS WITH SCANNER Y220_3A1059 Scanner Installation 1. Connect the scanner connector to the diagnostic socket. 2. Turn the ignition switch to “ON” position. 3. Select [DIAGNOSTICS] in [MAIN MENU] screen and press [ENTER]. 4. Select [REXTON] in [VEHICLE SELECTION] screen and press and press [ENTER]. 5.
Page 56 3A1-53 TCU Coding for DC 5-Speed Automatic Transmission If the TCU or automatic transmission has been replaced, the TCU should be coded with Scan-i. Entering the diagnosis procedures 1. Select “6] ECU REPROGRAM” and press in MAIN MENU screen. Y220_10060 2.
Page 57 3A1-54 5. Select “1] Y220 DE27DT” and press in TCU CODING screen. Y220_10063 6. If the message as shown in the figure appears, select “YES” to start coding and press Y220_10064 7. If the message as shown in the figure appears, turn the ignition key to “OFF”...
Page 58 3A1-55 DTC (Diagnosis Trouble Code) of DC5AT Trouble Defectives Action Code P2000 Faulty TCU internal watchdog test - Self-diagnosis with IGN ON. - Cycle the IGN switch from OFF to ON. Check and replace TCU if the trouble still exists. P2001 Faulty TCU internal watchdog - Self-diagnosis.
Page 59 3A1-56 Trouble Defectives Action Code P2101 1-2, 4-5 shift solenoid valve - short - When 1-2 or 4-5 shift solenoid valve is defective. - Measure the resistance of 1-2 or 4-5 shift solenoid valve (turn the IGN OFF, then disconnect TCU connector). •...
Page 60 3A1-57 Trouble Defectives Action Code P2107 Defective modulator pressure sole- - Measure the resistance of modulator pressure solenoid valve (turn the noid valve IGN OFF, then disconnect TCU connector). • TCU connector terminals: B5, B3 • Specified value: 5.0 ± 0.2 Ω - Triggered emergency mode when the defective is detected.
Page 61 3A1-58 Trouble Defectives Action Code P2301 Faulty CAN communication - Turn the IGN OFF, then disconnect TCU connector. - Check the communication line for open, short and contact. - Measure the resistance of CAN line: B1, B2 • Specified value: approx. 120 Ω P2310 CAN: Faulty brake system communi- - Check CAN communication line H and L.
Page 62 3A1-59 Trouble Defectives Action Code P2400 CAN: Faulty rear RH wheel speed - Check CAN communication line H and L. sensor signal - Check ABS/ESP unit. • Check wheel speed sensor connector. • Check the air gap between tooth wheel and wheel speed sensor. Check tooth wheel installation.
Page 63 3A1-60 Trouble Defectives Action Code P240A CAN: No engine rpm signal - Check CAN communication line H and L. - Check engine ECU. - Check the related harness for open, short and contact. P240B CAN: No engine coolant temperature - Check CAN communication line H and L. signal - Check engine ECU.
Page 64 3A1-61 HYDRAULIC SYSTEM STRUCTURE OF VALVE BODY Torque converter Oil pump Input shaft Output shaft B1 C1 C2 B3 C3 B2 Parking lock gear Intermediate shaft Center planetary gear Valve body Stator shaft Lockup clutch Y220_3A1066 1. Shift housing 8. Shift valve pressure control valve 2.
Page 65 3A1-62 HYDRAULIC CIRCUIT M/P S/V S/P S/V 1-2/4-5 shift shift Lockup S/V 2-3 shift S/V Y220_3A1062 DC 5-SPEED AUTOMATIC TRANSMISSION CHANGED BY EFFECTIVE DATE REXTON SM - 2004.4 AFFECTED VIN...
Page 66 3A1-63 1. Selector valve 21. Shift valve pressure control valve 2. 2-3 overlap control valve 22. Lock-up clutch control valve 3. Lubricating pressure control valve 24. 2-3 shift valve 4. Operating pressure control valve 25. 2-3 command valve 5. Holding pressure shift valve 26.
Page 67 3A1-64 Oil Pressure Modulating pressure Shift pressure control control solenoid valve solenoid valve Y220_3A1068 1. Lubricating pressure control valve 6. Shift pressure control valve 2. Operating pressure control valve 7. Oil pump 3. One-way throttle valve 8. Drain 4. Shift valve pressure pressure control valve p-A.
Page 68 3A1-65 Lubricating Pressure (p-SM) This pressure limits the pressure in torque converter and lubricates and cools the mechanical transmission parts. At the operating pressure control valve, excess fluid is diverted to the lubricating pressure control valve (1) and, from there, regulated for transmission lubrication use (including torque converter). Control Valve Pressure (p-RV) The control valve pressure is set at the control pressure regulating valve (5) in relation to the operating pressure up to 8 bar.
Page 69 3A1-66 Shift Groups The hydraulic control range (including shift elements), which is responsible for the pressure distribution before, during and after a gear change, is designated a shift group. The hydraulic system consists of 3 shift groups. A shift group can be in two phases. •...
Page 70 3A1-67 HYDRAULIC CIRCUIT WHEN STARTING ENGINE Selector Lever “N” 3-4 shift solenoid valve Y220_3A1075 1. Selector valve B2a. B2 piston 5. 3-4 holding pressure shift valve B2b. Opposite face of B2 piston 6. 3-4 command valve m. Annular surface 7. 3-4 shift pressure shift valve p-A.
Page 71 3A1-68 Hydraulic Circuit When Moving Selector Lever From “N” to “D” (Shift Phase) 3-4 shift solenoid valve Y220_3A1076 1. Selector valve 5. 3-4 holding pressure shift valve B2a. B2 piston 6. 3-4 Command valve B2b. Opposite face of B2 piston 7.
Page 72 3A1-69 Hydraulic Circuit When Selector Lever is in “D” Position (1st Gear) 3-4 shift solenoid valve Y220_3A1077 1. Selector valve B2a. B2 piston 5. 3-4 holding pressure shift valve B2b. Opposite face of B2 piston 6. 3-4 Command valve m. Annular surface 7.
Page 73 3A1-70 Hydraulic Circuit After Shifted to 1st Gear 1-2/4-5 shift solenoid valve Y220_3A1078 14. 1-2/4-5 command valve 0. Return flow to oil sump 15. 1-2/4-5 holding pressure shift valve p-A. Operating pressure 16. 1-2/4-5 shift valve p-MOD. Modulating pressure 18. 1-2/4-5 pressure overlap control valve p-S.
Page 74 3A1-71 Hydraulic Circuit During Shift Phase 1-2/4-5 shift solenoid valve Y220_3A1079 14. 1-2/4-5 command valve 0. Return flow to oil sump 15. 1-2/4-5 holding pressure shift valve p-A. Operating pressure 16. 1-2/4-5 shift valve p-MOD. Modulating pressure 18. 1-2/4-5 pressure overlap control valve p-S.
Page 75 3A1-72 Hydraulic Circuit After Completed Gear Change 1-2/4-5 shift solenoid valve Y220_3A1080 14. 1-2/4-5 command valve 0. Return flow to oil sump 15. 1-2/4-5 holding pressure shift valve p-A. Operating pressure 16. 1-2 /4-5 shift valve p-MOD. Modulating pressure 18. 1-2/4-5 pressure overlap control valve p-S.
Page 76 3A1-73 STRUCTURE OF ELECTRO-HYDRAULIC CONTROL MODULE (SHIFT PLATE) Y220_3A1081 A. Adjusting valve: Operating pressure, Lubricating C. 3-4 shift group pressure, 2-3 group overlap D. 2-3 shift group, Clutch lockup control valve, shift B. 1-2/4-5 shift group, control valve: Control valve valve B2 pressure, Shift valve pressure Rear Section...
Page 77 3A1-74 Left Section Y220_3A1083 1. Shift housing 8. Shift valve pressure control valve 2. 1-2/4-5 command valve 9. Torque converter lockup clutch control valve 3. 1-2/4-5 holding pressure shift valve 10. 2-3 shift pressure shift valve 4. 1-2/4-5 shift pressure shift valve 11.
Page 78 3A1-75 Removal and Installation 1. Remove the leaf spring (5). 2. Remove the bolt (1). Installation Notice Tightening torque 8 Nm 3. Remove the shift housing (4) from valve housing (2). Notice Befor installation, make sure to insert the dowel pin into correct position.
Page 79 3A1-76 REMOVAL AND INSTALLATION (DC 5-SPEED A/T) COMPONENTS LOCATOR Y220_3A1086 1. Torque converter housing 1. Oil filler pipe 2. Plug connector 2. Drain plug 3. Oil line 3. Union bolt 4. Shield 4. Oil line 5. Bolts 5. Plug connector 6.
Page 80 3A1-77 Removal and Installation Preceding work: Disconnect negative battaery cable. * Make sure that the oil cooler pipe hose is not be twisted, oil cooler pipe (radiator side) is not clogged. If it is con- taminated with foreign materials, thoroughly clean before replacing transmission assembly (This work is neces- sary when removing and installing the radiator).
Page 81 3A1-78 2. Remove the cross member and insulator under the connection area of transfer case and transmission. Left/Right: 36 ~ 44 Nm Tightening torque Center: 20 Nm Y220_3A1089 3. Separate the air bleed hose from transfer case. Y220_3A1090 4. Disconnect transmission wiring harness from transfer case.
Page 82 3A1-79 6. Disconnect selector lever. Notice Place the selector lever at “P” position when removing/installing selector lever and wire cable. Y220_3A1093 7. Unscrew the bolts and remove the oil dipstick pipe and mounting bracket. Installation Notice Tightening torque 14 Nm Y220_3A1094 8.
Page 83 3A1-80 9. Unscrew the plug connector shield bolt and remove the plug connector from automatic transmission. Y220_3A1096 10. Remove the torque converter bolts from drive plate. Installation Notice Tightening torque 42 Nm Y220_3A1097 DC 5-SPEED AUTOMATIC TRANSMISSION CHANGED BY EFFECTIVE DATE REXTON SM - 2004.4 AFFECTED VIN...
Page 84 3A1-81 11. Unscrew the transmission mounting bolts and remove the transmission assembly. Tightening torque 50 ~ 60 Nm Notice Be careful not to drop torque conver. Y220_3A1098 12. Remove the torque converter with special tool. Notice Apply a small amount of transmission oil on drive flange before installing torque converter.
Page 85 3A1-82 Selector Assembly - Removal and Installation 1. Separate selector lever. Notice Place the selector lever at “P” position when removing/ installing selector lever and wire cable. Y220_3A1101 2. Remove the console box (refer to “Body” section). 3. Remove the senter and rear air duct. Y220_3A1102 4.
Page 86 3A1-83 DISASSEMBLY AND REASSEMBLY (DC 5-SPEED A/T) COMPONENTS Torque converter Left side view Oil pump Input shaft Output shaft C1 C2 B3 C3 B2 Parking lock gear Intermediate shaft Center planetary gear Valve body Stator shaft Lockup clutch Right side view Front view Rear view Under view...
Page 87 3A1-84 COMPONENTS ASSEMBLY Torque converter Oil pump C3 assembly Input shaft Output shaft C1 C2 B3 C3 B2 C2 assembly Parking lock gear Intermediate shaft Center planetary gear Valve body Stator shaft B3 assembly Housing assembly Lockup clutch C1 assembly B2 assembly B1 assembly Oil pump...
Page 88 3A1-85 Friction Disc Transmission Friction Disc Remark Numbers W5A300 Single Dual Single Single Dual Dual (G32D: 4WD) Type face face face face face face Numbers W5A400 Single Dual Single Single Dual Dual (D27DT: 4WD) Type face face face face face face Tightening Torque Tightening...
Page 89 3A1-86 DISASSEMBLY AND REASSEMBLY Valve Body Assembly 5. Valve body Y220_3A1107 1. Guide bush 5-3. Pin 5-9. Solenoid valve 2. Drain plug 5-4. Plate leaf spring 5-10. Plate spring 3. Bolts 5-5. Bolts 5-11. Screw 4. Oil filter 5-6. Electric kit 5-12.
Page 90 3A1-87 Disassembly and Reassembly Preceding work: Install the transmission on work bench. Note • To eliminate unnecessary working time and process, prepare general tools, special tools, and gaskets before starting work. • The automatic transmission is very precise equipment. Keep the transmission clean and tighten the bolts with specified tightening torque.
Page 91 3A1-88 4. Unscrew the bolts and remove the valve body from transmission housing. Installation Notice Tightening torque 8 Nm Y220_3A1112 5. Disassembly and reassemblt the valve body assembly. 5-1. Remove the solenoid valve cap. Y220_3A1113 5-2. Unscrew the bolts on solenoid valve and remove the leaf springs.
Page 92 3A1-89 Notice 1. Make sure to install the solenoid valves at correct locations. 2. Check the O-rings, and replace if necessary. Y220_3A1116 5-4. Remove the electronic control module (Y3/6) from shift plate. Notice Correctly align the electronic control module onto the shift plate by using two central pins when installing.
Page 93 3A1-90 Converter Housing and Transmission Housing Transmission housing Converter housing assembly Y220_3A1118 Disassembly and Reassembly 1. Install the transmission assembly on work bench. Y220_3A1119 2. Remove the rear extension housing from transmission housing. Installation Notice Tightening torque 30 ~ 35 Nm Y220_3A1120 DC 5-SPEED AUTOMATIC TRANSMISSION CHANGED BY...
Page 94 3A1-91 3. Stretch out the bent point in 12-sided collar nut on output shaft. Y220_3A1121 4. Unscrew the collar nut with special tool and remove output shaft flange. Installation Notice Tightening torque 200 Nm * Bend the collar nut to lock it during installation. Y220_3A1122 5.
Page 95 3A1-92 7. Remove the ball bearing from transmission housing. 7. Remove the ball bearing from transmission housing. • Install the flare clamping pliers. • Install the flare clamping pliers. • Install the puller onto inner bearing race. • Install the puller onto inner bearing race. •...
Page 96 3A1-93 Converter Housing Assembly Clutch C3 Clutch C2 Clutch C1 Brake B1 Oil pump Y220_3A1130 DC 5-SPEED AUTOMATIC TRANSMISSION CHANGED BY REXTON SM - 2004.4 EFFECTIVE DATE AFFECTED VIN...
Page 97 3A1-94 Disassembly and Reassembly 1. Remove the clutch C3 from converter housing assembly. Y220_3A1131 2. Remove the clutch C2 from converter housing assembly. Y220_3A1132 3. Remove the clutch C1 from converter housing assembly. Y220_3A1133 4. Remove the brake B1. 4-1. Remove the bolts on brake B1. Installation Notice Tightening torque 16 Nm...
Page 98 3A1-95 4-2. Remove the bolts in converter housing. Installation Notice Tightening torque 8 Nm Y220_3A1135 4-3. Remove the brake B1 from converter housing. Y220_3A1136 4-4. Separate the plate from valve body. Notice • Install two bolts on the opposite side of disc brake B1 and tap the surface of disc brake B1 with plastic hammer to remove it ftom converter housing.
Page 99 3A1-96 5-1. Remove the pump gears (1, 2) from pump housing. Y220_3A1139 5-2. Check the radial seal ring (3), and replace if necessary. 5-3. Replace the O-ring (4) with new one. Notice • Lubricate the pump gears (1, 2) before installation. •...
Page 100 3A1-97 Transmission Housing Assembly Parking lock gear Brake B2 Brake B3 Snap ring Components of selector lever Y220_3A1141 DC 5-SPEED AUTOMATIC TRANSMISSION CHANGED BY REXTON SM - 2004.4 EFFECTIVE DATE AFFECTED VIN...
Page 101 3A1-98 Disassembly and Reassembly 1. Install the transmission assembly on work bench. Y220_3A1142 2. Remove the snap ring from transmission housing. Y220_3A1143 3. Remove the spring washer and disc pack B3 from transmission housing. Notice • To make the removal easier, remove the disc pack B3 while compressing it.
Page 102 3A1-99 5. Remove the disc brake B2 from transmission housing. Y220_3A1146 6. Remove the parking lock gear. Y220_3A1147 7. Remove the fixing bolts for range selector lever. Installation Notice Tightening torque 8 Nm Notice Check the sealing ring for damage. Y220_3A1148 8.
Page 103 3A1-100 9. Remove the snap rings from parking lock pawl. Y220_3A1150 10. Remove the pin from transmission housing. Y220_3A1151 11. Remove the parking lock pawl from transmission housing. Y220_3A1152 DC 5-SPEED AUTOMATIC TRANSMISSION CHANGED BY EFFECTIVE DATE REXTON SM - 2004.4 AFFECTED VIN...
Page 104 3A1-101 Components of Each Assembly Clutch C1 Clutch C2 Clutch C3 Y220_3A1153 DC 5-SPEED AUTOMATIC TRANSMISSION CHANGED BY REXTON SM - 2004.4 EFFECTIVE DATE AFFECTED VIN...
Page 105 3A1-102 Clutch C1 Clutch C2 Clutch C3 1. Sealing ring in disc carrier 11. Front planetary gear set 24. Clutch C3 2. Piston 12. Gear wheel 25. Sealing ring 3. Sealing ring in piston 13. Snap ring 26. Piston 4. Return spring 14.
Page 106 3A1-103 Multi-disc brake B1 Multi-disc brake B2 Y220_3A1155 Multi-disc brake B1 Multi-disc brake B2 1. Disc brake B1 8. Disc carrier B2 15. Spring plate 2. Piston 9. Sealing ring 16. Snap ring 3. Return spring 10. Sealing ring 17. Piston guides in B2 and B3 4.
Page 107 3A1-104 Rear gear set and center output shaft Rear freewheel and rear hollow shaft Y220_3A1157 Rear gear set and center output shaft Rear freewheel and rear hollow shaft 1. Output shaft in center gear set 12. Hollow shaft 2. Needle bearing 13.
Page 108 3A1-105 Installation 1. Measure the clearance between the ball bearing and the parking lock gear. • Place the straightener on top of transmission housing and measure the distance of “a” with auge. • Measure the distance (b) from straightener to the ball bearing groove on mating surface with gauge.
Page 109 3A1-106 SPECIAL TOOLS AND EQUIPMENT Name and Part Number Application W 126 589 01 62 00 Removal and installation of torque converter Handle Y220_3A1176 Y220_3A1177 W 116 589 06 59 00 Fixing automatic transmission Fixture stand Y220_3A1178 Y220_3A1179 W 140 589 12 15 00 Installation of sealing ring Drift punch Y220_3A1180...
Page 110 3A1-107 Name and Part Number Application W 140 589 34 63 00 Fixing automatic transmission Mounting plate Y220_3A1184 Y220_3A1185 W 140 589 06 34 00 Removal and installation of transmission housing ball bearing Collet chuck Y220_3A1186 Y220_3A1187 W 140 589 13 43 00 Removal and installation of B1, B2, B3 piston Piston puller Y220_3A1188...
Page 111 3A1-108 Name and Part Number Application Measuring the clearance between ball 128 589 04 31 00 bearing and parking lock gear Straightedge Y220_3A1192 Y220_3A1193 Compressor Compressing clutch and disc brake Y220_3A1194 Y220_3A1195 DC 5-SPEED AUTOMATIC TRANSMISSION CHANGED BY EFFECTIVE DATE REXTON SM - 2004.4 AFFECTED VIN...
Page 112 3A2-1 SECTION 3A2 ´Ü¿ø 00 BTRA 4 AUTO TRANSMISSION Table of Contents DESCRIPTION AND OPERATION ....3A2-2 TROUBLE CODE DIAGNOSIS BTRA M74 4WD automatic transmission ..3A2-2 - GASOLINE VEHICLE ......3A2-50 Operators interfaces ....... 3A2-3 TCU diagnostic system overview ..3A2-50 Control systems ........
Page 113 3A2-2 DESCRIPTION AND OPERATION BTRA M74 4WD AUTOMATIC The TCM utilizes throttle position, rate of throttle open- ing, engine speed, vehicle speed, transmission fluid TRANSMISSION temperature, gear selector position and mode selector The BTR Automotive Model 74 Four Speed Automatic inputs, and in some applications a Kickdown Switch to Transmission is an electronically controlled overdrive four control all shift feel and shift schedule aspects.
Page 114 3A2-3 OPERATORS INTERFACES • 2 - Manual 2 provides two gear ratios (first and second). It is used to provide more power when climbing hills or There are three operator interfaces as the following; engine braking when driving down a steep hill or starting •...
Page 115 3A2-4 CONTROL SYSTEMS Processing logic Shift schedule and calibration information is stored in an BTRA M74 4WD automatic transmission consists of two Erasable Programmable Read Only Memory (EPROM). control systems. One is the electronic control system that Throttle input calibration constants and the diagnostics monitors vehicle parameters and adjusts the transmission information are stored in Electrically Erasable Program- performance.
Page 116 3A2-5 Y220_3A2030 TCM inputs To function correctly, the TCM requires engine speed, vehicle Resistance (Ohms) speed, transmission fluid temperature, throttle position, gear Temperature (°C) Minimum Maximum position and Kickdown Switch inputs to determine the vari- able pressure solenoid current ramp and on/off solenoid states. 13,638 17,287 This ensures the correct gear selection and shift feel for all...
Page 117 3A2-6 Pin No. Codes and colors in Solenoid Loom ously monitors the maximum and minimum throttle po- tentiometer voltages and, if a change occurs, stores the Pin No. Wire Color Connects to new voltage values. Solenoid 1 However these limits will be lost and will require relearning Blue Solenoid 2 should a new TCU be installed, or the throttle calibration...
Page 118 3A2-7 Solenoids Readings for Resistance / Shift Lever Positions The TCM controls seven solenoids. Solenoids 1 to 6 (S1 Resistance (kΩ Ω Ω Ω Ω ) Shift Lever Position to S6) are mounted in the valve body, while Solenoid 7 Manual 1 1 ~ 1.4 (S7) is mounted in the pump cover.
Page 119 3A2-8 Solenoid Operation during Gearshifts Shift To Initiate Shift Typical S5 Current Ramp To Complete Shift S1 OFF 750 mA to 600 mA S4 OFF S4 ON S1 OFF S3 OFF S2 OFF 850 mA to 750 mA S4 OFF S3 ON S4 ON S2 OFF...
Page 120 3A2-9 Solenoid valve symbols (ON/OFF solenoids) When the VPS is at standby, that is no gearshift is taking place, the VPS current is set to 200 mA giving maximum The solenoid symbol shown adjacent to each solenoid on output pressure. the hydraulic system schematics indicates the state of the oil flow through the solenoid valve with the power ON Under steady state conditions the band and clutch regula-...
Page 121 3A2-10 Data Link Connector (DLC) The pump cover contains the following; The Data Link Connector (DLC) is a multiple cavity • Primary regulator valve for line pressure connector. The DLC provides the means to access the • Converter clutch regulator valve serial data from the TCM.
Page 122 3A2-11 HYDRAULIC CONTROL CIRCUIT Y220_3A208A BTRA 4 AUTO TRANSMISSION CHANGED BY REXTON SM - 2004.4 EFFECTIVE DATE AFFECTED VIN...
Page 123 3A2-12 Valve Body Y220_3A2110 2-3 shift valve Y220_3A2090 The 2-3 shift valve is a two position valve. It is used on all Manual valve 2-3 and 3-2 gearshifts. The manual valve is connected to the vehicle selector The switching of this valve is achieved by S2 which is lo- mechanism and controls the flow of oil to the forward and cated at the end of the valve spool.
Page 124 3A2-13 The 3-4 shift valve also switches during 1-2 and 2-1 gear- Heavy throttle application causes the normally open S6 to shifts where its function is to apply the overrun clutch (C4) open (switch Off) thus closing line 500 and opening S6 to in second gear but to release it in first gear.
Page 125 3A2-14 S1- S2 pressure is exhausted and the valve is held in the lockout position by the spring. In this position, engage- ment of B2 is prohibited. This feature protects the transmission from abuse by pre- venting the undesirable application of B2 at high speed, and by providing a reverse lockout function.
Page 126 3A2-15 Y220_3A2200 Y220_3A2220 Converter clutch regulator valve B1R exhaust valve The converter clutch regulator valve regulates the pres- The B1R exhaust valve is a two position spring loaded sure of the oil which applies the converter clutch. Input oil valve located in the transmission case directly adjacent to from the line 500 circuit is regulated within the valve, with the front servo.
Page 127 3A2-16 • Gear set-sprag-centre support accomplished by re-applying the B1 band and overrun- ning the 3-4 OWC. Reverse gear is engaged by applying • C1 -C2 -C3 -C4 clutch sub-assembly the C3 clutch and the B2 band. • Pump assembly The C4 clutch is applied in the Manual 1, 2 and 3 ranges •...
Page 128 3A2-17 Torque converter Clutch packs The torque converter consists of a turbine, stator pump, There are four clutch packs. All clutch packs are com- impeller and a lock-up damper and piston assembly. As posed of multiple steel and friction plates. in conventional torque converters, the impeller is attached C1 CLUTCH: When applied, this clutch pack allows the to the converter cover, the turbine is splined to the input...
Page 129 3A2-18 Bands The B2 band is a solid band which is engaged by the rear servo piston. B2 is activated in Park, Reverse, Neutral The transmission utilizes two bands, the B1 band and Manual 1. When activated B2 prevents the planet car- (sometimes known as the 2-4 band), and the B2 band rier assembly from rotating.
Page 130 3A2-19 POWER FLOWS The power flows for the various transmission selections • Power Flow - Drive 3 are listed below; • Power Flow - Drive 3 Lock Up • Power Flow - Neutral and Park • Power Flow - Drive 4 (Overdrive) •...
Page 131 3A2-20 PARK AND NEUTRAL Y220_3A231A BTRA 4 AUTO TRANSMISSION CHANGED BY EFFECTIVE DATE REXTON SM - 2004.4 AFFECTED VIN...
Page 132 3A2-21 Power flow - Park and neutral • Line (pump) pressure is applied to the Primary Regu- lator Valve (PRV) and to the solenoid supply pressure In Park and Neutral, there is no drive to the planetary gear regulator valve. set.
Page 133 3A2-22 REVERSE Y220_3A233A BTRA 4 AUTO TRANSMISSION CHANGED BY EFFECTIVE DATE REXTON SM - 2004.4 AFFECTED VIN...
Page 134 3A2-23 Power flow - Reverse Control In Reverse, transmission drive is via the input shaft and To maintain this arrangement in the steady state sole- the forward clutch cylinder to the hub of the C3 clutch. noids and valves are activated as follows; The elements of the transmission function as follows;...
Page 135 3A2-24 MANUAL 1 Y220_3A235A BTRA 4 AUTO TRANSMISSION CHANGED BY EFFECTIVE DATE REXTON SM - 2004.4 AFFECTED VIN...
Page 136 3A2-25 Power flow - Manual 1 Control In Manual 1, transmission drive is via the input shaft to the To maintain this arrangement in the steady state sole- forward clutch cylinder. The elements of the trans-mission noids and valves are activated as follows; function as follows;...
Page 137 3A2-26 DRIVE 1 Y220_3A237A BTRA 4 AUTO TRANSMISSION CHANGED BY EFFECTIVE DATE REXTON SM - 2004.4 AFFECTED VIN...
Page 138 3A2-27 Power flow - Drive 1 Control In Drive 1, transmission drive is via the input shaft to the To maintain this arrangement in the steady state sole- forward clutch cylinder. The elements of the transmission noids and valves are activated as follows: function as follows: •...
Page 139 3A2-28 DRIVE 2 AND MANUAL 2 Y220_3A239A BTRA 4 AUTO TRANSMISSION CHANGED BY EFFECTIVE DATE REXTON SM - 2004.4 AFFECTED VIN...
Page 140 3A2-29 Power flow - Drive 2 and manual 2 • Drive (line pressure) oil from the manual valve en-gages the C2 clutch. In Drive 2 and Manual 2, transmission drive is via the input shaft and forward clutch cylinder. The elements of the trans- •...
Page 141 3A2-30 DRIVE 3 AND MANUAL 3 Y220_3A241A BTRA 4 AUTO TRANSMISSION CHANGED BY EFFECTIVE DATE REXTON SM - 2004.4 AFFECTED VIN...
Page 142 3A2-31 Power flow - Drive 3 and manual 3 • The band apply feed regulator valve supplies 2nd oil (regulated to line pressure multiplied by the valve ra- In Drive 2 and Manual 2, transmission drive is via the input tio) to the Band Apply Feed (BAF) circuit.
Page 143 3A2-32 DRIVE 3 LOCK UP AND MANUAL 3 LOCK UP Y220_3A243A BTRA 4 AUTO TRANSMISSION CHANGED BY EFFECTIVE DATE REXTON SM - 2004.4 AFFECTED VIN...
Page 144 3A2-33 Power flow - Drive 3 lock up and manual 3 lock • When S7 is switched ON, S7 feed oil to the converter clutch control valve is switched OFF and allowed to exhaust through the S7 solenoid. This allows the valve In Drive 3 Lock Up and Manual 3 Lock Up, transmission to move to the clutch engage position.
Page 145 3A2-34 DRIVE 4 (OVERDRIVE) Y220_3A245A BTRA 4 AUTO TRANSMISSION CHANGED BY EFFECTIVE DATE REXTON SM - 2004.4 AFFECTED VIN...
Page 146 3A2-35 Power flow - Drive 4 (Overdrive) • The 1-2 shift valve is held in the fourth gear position by S2 oil pressure. In Drive 4 (Overdrive), transmission drive is via the input shaft to the forward clutch cylinder. • 2nd oil (line pressure) from the 1-2 shift valve is di- rected to the band apply feed regulator valve, and to The elements of the transmission function as follows;...
Page 147 3A2-36 DRIVE 4 LOCK UP Y220_3A247A BTRA 4 AUTO TRANSMISSION CHANGED BY EFFECTIVE DATE REXTON SM - 2004.4 AFFECTED VIN...
Page 148 3A2-37 Power flow - Drive 4 lock up • Regulated apply feed oil, drived from drive oil at the converter clutch regulator valve, is directed by the In Drive 4 Lock Up, transmission drive is the same as for converter clutch control valve to the engage side of the Drive 4 but with the application of the converter lock up converter clutch.
Page 149 3A2-38 DIAGNOSTIC INFORMATION AND PROCEDURES DIAGNOSIS BASIC KNOWLEDGE REQUIRED FUNCTIONAL CHECK PROCE- DURE You must be familliar with some basic electronics to use this section of the Service Manual. They will help you to Begin with the Functional Check Procedure which pro- follow diagnostic procedures.
Page 150 3A2-39 TRANSMISSION FLUID LEVEL 4. Place a fluid container below the fluid filler plug. 5. Clean all dirt from around the fluid filler plug. Remove SERVICE PROCEDURE the fluid filler plug. Clean the filler plug and check This procedure is to be used when checking a concern that there is no damage to the ‘O’...
Page 151 3A2-40 Powder method 4. Lower the vehicle with the filler pump still connected and start the vehicle in P (Park) with the parking brake 1. Thoroughly clean the suspected leak area. and the brake applied. With the engine idling, move 2.
Page 152 3A2-41 ELECTRICAL / GARAGE SHIFT 7. Monitor the GEAR SHIFT LEVER POSITION signal and move the gear shift control lever through all the TEST ranges. This preliminary test should be performed before a hoist or • Verify that the GEAR SHIFT LEVER POSITION road test to make sure electronic control inputs are con- value matches the gear range indicated on the nected and operating.
Page 153 3A2-42 Throttle position calibration Should the throttle position data stored in the TCU be lost or be out of specification, as indicated by a diagnostic trouble message, it may be re-established by the follow- ing procedure. • Check that the hot engine idle speed is within specfication.
Page 154 3A2-43 SYMPTOM DIAGNOSIS DRIVE FAULTS Condition Possible Causes Action No Drive in D • Insufficient auto transmission fluid. • Check the fluid level. Top up as necessary. • Blocked feed in C1/C2 cylinder. • Inspect and clean C1/C2 feed. • “Z” link displaced. •...
Page 155 3A2-44 FAULTY SHIFT PATTERN Condition Possible Causes Action 2-3 shift only (no 4th or 1st) • S1 always OFF. • Inspect S1. Repair or replace as necessary. • Check for 12 Volts applied to S1 at all times or for wiring fault. •...
Page 156 3A2-45 Condition Possible Causes Action Harsh 2-3 shift • Jammed band 1 release valve. • Inspect the release valve. Repair or replace as necessary. • Faulty S3 or S2 solenoid. • Inspect S3 or S2. Repair or replace as necessary. •...
Page 157 3A2-46 SHIFT QUALITY FAULTS Condition Possible Causes Action • Incorrect auto transmission fluid • Drain and fill with specified ATF. All Shifts Firm (ATF). • S5 faulty won, or incorrectly fitted. • Check that S5 is fitted correctly, or replace S5. •...
Page 158 3A2-47 Condition Possible Causes Action Harsh 1-2 shift • Faulty inhibitor switch. • Check the resistance. Replace the inhibitor switch as necessary. • Faulty throttle position sensor. • Inspect and replace the sensor as necessary. • Incorrect front band adjustment. •...
Page 159 3A2-48 AFTER TEARDOWN FAULTS Condition Possible Causes Action C2 burnt • Gear shift lever linkage out of • Inspect, repair C2 and adjust the adjustment. linkage as necessary. • S6 foiled - stuck low. • Repair C2. Inspect, repair or replace S6 as necessary.
Page 160 3A2-49 Condition Possible Causes Action Firm converter lock or unlock • Input shaft “O” ring missing or • Inspect and replace the “O” ring as damaged. necessary. • Converter clutch regulator valve in • Inspect and refit the valve as backwards.
Page 161 3A2-50 TROUBLE CODE DIAGNOSIS - GASOLINE VEHICLE TCU DIAGNOSTIC SYSTEM OVER- Board Diagnostic (EOBD) compliance, the Engine Con- trol Module (ECM) provides the communication link to the VIEW EOBD scan tool to pass on any EOBD relevant codes from the TCM. The table below contains a list of all sup- Notice ported DTCs and the classification of each for EOBD purposes.
Page 162 3A2-51 DIAGNOSTIC TROUBLE CODES (Cont’d) Description Type P1734 Solenoid 2 Circuit Open P1735 Solenoid 3 Circuit Open P1736 Solenoid 4 Circuit Open P1737 Solenoid 5 Circuit Open P1738 Solenoid 6 Circuit Open P1739 Solenoid 7 Circuit Open P1741 Solenoid 1 Circuit Short P1742 Solenoid 2 Circuit Short P1743...
Page 163 3A2-52 TROUBLE CODE DIAGNOSIS - DIESEL VEHICLE TCM DIAGNOSTIC SYSTEM OVER- CLEARING TROUBLE CODES VIEW TCM DTCs should be cleared after repairs have been completed. Some diagnostic tables will tell you to clear the codes before using the chart, which will help to find Notice the cause of the problem more quickly.
Page 164 3A2-53 DIAGNOSTIC TROUBLE CODES (Cont’d) Description Solenoid 5 Circuit Open P1737 Solenoid 6 Circuit Open P1738 Solenoid 7 Circuit Open P1739 Solenoid 1 Circuit Short P1741 Solenoid 2 Circuit Short P1742 Solenoid 3 Circuit Short P1743 Solenoid 4 Circuit Short P1744 Solenoid 5 Circuit Short P1745...
Page 165 3A2-54 YAD5A010 TCM DIAGNOSTIC SYSTEM CHECK Circuit Description Diagnostic Aids The Transmission Control Module (TCM) Diagnistic Sys- An intermittent fault may be caused by a poor connec- tem Check is the starting point for any driveability com- tion, rubbed-through wire insulation or a wire broken in- plaint diagnosis.
Page 166 3A2-55 TCM Diagnostic System Check (Cont’d) Step Action Value(s) 1. Turn the ignition OFF. 2. Disconnect the TCM connector B. 3. Turn the ignition ON. 4. Check the serial data line from TCM connector terminal A22 to Data Link Connector (DLC) connector terminal 14 for an open, short to ground, or short to voltage.
Page 167 3A2-56 Y220_3A2020 DIAGNOSTIC TROUBLE CODE (DTC) P0706 TRANSMISSION RANGE SENSOR CIRCUIT RANGE/PERFORMANCE Circuit Description Action Taken When the DTC Sets The Transmission Range (TR) sensor is incorporated in • The Malfunction Indicator Lamp (MIL) will illuminate the inhibitor switch mounted on the side of the transmis- on the second consecutive driving cycle with the DTC sion case.
Page 168 3A2-57 DTC P0706 Transmission Range Sensor Circuit Range/Performance Step Action Value(s) Perform a Transmission Control Module (TCM) Go to “TCM Diagnostic System Check. Diagnostic Is the check performed? Go to Step 2 System Check” 1. Install the scan tool. 2. Turn the ignition ON, with the engine OFF. 3.
Page 169 3A2-58 Y220_3A2020 DIAGNOSTIC TROUBLE CODE (DTC) P0707 TRANSMISSION RANGE SENSOR CIRCUIT LOW INPUT Circuit Description Conditions for Clearing the DTC The Transmission Range (TR) sensor is incorporated in • The DTC will clear when the malfunction has not the inhibitor switch mounted on the side of the transmis occurred for 3 seconds.
Page 170 3A2-59 DTC P0707 Transmission Range Sensor Circuit Low Input Step Action Value(s) Perform a Transmission Control Module (TCM) Go to “TCM Diagnostic System Check. Diagnostic Is the check performed? Go to Step 2 System Check” 1. Turn the ignition ON, with the engine OFF. 2.
Page 171 3A2-60 Y220_3A2020 DIAGNOSTIC TROUBLE CODE (DTC) P0708 TRANSMISSION RANGE SENSOR CIRCUIT HIGH INPUT Circuit Description Conditions for Clearing the DTC The Transmission Range (TR) sensor is incorporated in • The DTC will clear when the malfunction has not the inhibitor switch mounted on the side of the transmis- occurred for 3 seconds.
Page 172 3A2-61 DTC P0707 Transmission Range Sensor Circuit High Input Step Action Value(s) Perform a Transmission Control Module (TCM) Go to “TCM Diagnostic System Check. Diagnostic Go to Step 2 System Check” Is the check performed? 1. Turn the ignition ON, with the engine OFF. 2.
Page 173 3A2-62 DTC P0707 Transmission Range Sensor Circuit High Input (Cont’d) Step Action Value(s) 1. Using the scan tool, clear the DTCs. 2. Road test the vehicle within the conditions for setting this DTC as specified in the text. Does the scan tool indicate that this diagnostic has Go to Step 12 Go to Step 2 run and passed?
Page 174 3A2-63 BLANK BTRA 4 AUTO TRANSMISSION CHANGED BY REXTON SM - 2004.4 EFFECTIVE DATE AFFECTED VIN...
Page 175 3A2-64 Y220_3A2030 DIAGNOSTIC TROUBLE CODE (DTC) P0710 TRANSMISSION FLUID TEMPERATURE SENSOR CIRCUIT MALFUNCTION Circuit Description Conditions for Clearing the DTC The Transmission Fluid Temperature (TFT) sensor is a ther- • The DTC will clear when the malfunction has not oc mistor located in the solenoid wiring loom within the valve curred for 3 seconds.
Page 176 3A2-65 DTC P0710 Transmission Fluid Temperature Sensor Circuit Malfunction Step Action Value(s) Perform a Transmission Control Module (TCM) Go to “TCM Diagnostic System Check. Diagnostic Is the check performed? Go to Step 2 System Check” 1. Install the scan tool. 2.
Page 177 3A2-66 DTC P0710 Transmission Fluid Temperature Sensor Circuit Malfunction (Cont’d) Step Action Value(s) 1. Turn the ignition OFF. 2. Disconnect the TCM connector B. 3. Turn the ignition ON. 4. Check the TFT sensor ground circuit for an open. Is a problem found? Go to Step 12 Go to Step 14 Repair the TFT ground circuit for an open.
Page 178 3A2-67 BLANK BTRA 4 AUTO TRANSMISSION CHANGED BY REXTON SM - 2004.4 EFFECTIVE DATE AFFECTED VIN...
Page 179 3A2-68 Y220_3A2040 DIAGNOSTIC TROUBLE CODE (DTC) P0790 NORMAL/PERFORMANCE SWITCH CIRCUIT MALFUNCTION Circuit Description Conditions for Clearing the DTC The driving mode selector switch is located on the center • The DTC will clear after 3 seconds without the fault. console and allows the driver to select the driving mode. •...
Page 180 3A2-69 DTC P0790 Normal/Performance Switch Circuit Malfunction Step Action Value(s) Perform a Transmission Control Module (TCM) Go to “TCM Diagnostic System Check. Diagnostic Is the check performed? Go to Step 2 System Check” 1. Install the scan tool. 2. Turn the ignition ON, with the engine OFF. 3.
Page 181 3A2-70 DTC P0790 Normal/Performance Switch Circuit Malfunction (Cont’d) Step Action Value(s) Check for a poor connection at the mode switch and TCM connector and repair the malfunctioning termi- nals as necessary. Is a repair necessary? Go to Step 13 Go to Step 12 Replace the mode switch.
Page 182 3A2-71 BLANK BTRA 4 AUTO TRANSMISSION CHANGED BY REXTON SM - 2004.4 EFFECTIVE DATE AFFECTED VIN...
Page 183 3A2-72 Y220_3A2010 DIAGNOSTIC TROUBLE CODE (DTC) P1703 ENGINE SPEED SIGNAL ERROR Circuit Description Action Taken When the DTC Sets The Controller Area Network (CAN) connects various con- • Fault detection of some other signals will not possible. trol modules by using a twisted pair of wires, to share Conditions for Clearing the DTC common information.
Page 184 3A2-73 DTC P1703 Engine Speed Signal Error Step Action Value(s) Perform a Transmission Control Module (TCM) Go to “TCM Diagnostic System Check. Diagnostic Is the check performed? Go to Step 2 System Check” 1. Install the scan tool. 2. Turn the ignition ON, with the engine OFF. 3.
Page 185 3A2-74 Y220_3A2010 DIAGNOSTIC TROUBLE CODE (DTC) P1704 SHAFT SPEED SIGNAL ERROR Circuit Description Action Taken When the DTC Sets The Controller Area Network (CAN) connects various con- • All skip downshifts disabled and fourth gear will be in- trol modules by using a twisted pair of wires, to share hibited.
Page 186 3A2-75 Test Description • If diagnosing for a possible intermittent short or open condition, move or massage the wiring harness while The number(s) below refer to the step number(s) on the observing test equipment for a change. Diagnostic Table. • When ECM finds a fault on the vehicle speed signals, 3.
Page 187 3A2-76 Y220_3A2010 DIAGNOSTIC TROUBLE CODE (DTC) P1708 TCM SUPPLY VOLTAGE LOW Circuit Description Conditions for Clearing the DTC The battery voltage monitoring input is connected to the • The DTC will clear when the malfunction has not positive side of the battery. This signal is taken from the occurred for 30 seconds.
Page 188 3A2-77 DTC P1708 TCM Supply Voltage Low Step Action Value(s) Perform a Transmission Control Module (TCM) Go to “TCM Diagnostic System Check. Diagnostic Is the check performed? Go to Step 2 System Check” 1. Install the scan tool. 2. Turn the ignition ON, with the engine OFF. 3.
Page 189 3A2-78 Y220_3A2010 DIAGNOSTIC TROUBLE CODE (DTC) P1709 TCM SUPPLY VOLTAGE HIGH Circuit Description Diagnostic Aids The battery voltage monitoring input is connected to the • The voltage measured by the TCM corresponding to positive side of the battery. This signal is taken from the the battery supply voltage has been outside the range main supply to the TCM.
Page 190 3A2-79 DTC P1709 TCM Supply Voltage High Step Action Value(s) Perform a Transmission Control Module (TCM) Go to “TCM Diagnostic System Check. Diagnostic Go to Step 2 System Check” Is the check performed? 1. Install the scan tool. 2. Turn the ignition ON, with the engine OFF. 3.
Page 191 3A2-80 Y220_3A2190 DIAGNOSTIC TROUBLE CODE (DTC) P1710 AIR CONDITIONING SWITCH CIRCUIT MALFUNCTION Circuit Description Conditions for Clearing the DTC The Air Conditioning Switch circuit indicates the state of • The DTC will clear after 3 seconds without the fault. the air conditioning compressor clutch (on or off). This •...
Page 192 3A2-81 DTC P1710 Air Conditioning Switch Circuit Malfunction Step Action Value(s) Perform a TCM Diagnostic System Check. Go to “TCM Is the check performed? Diagnostic Go to Step 2 System Check” 1. Install the scan tool. 2. Turn the ignition ON, with the engine OFF. 3.
Page 193 3A2-82 DTC P1710 Air Conditioning Switch Circuit Malfunction (Cont’d) Step Action Value(s) 1. Using the scan tool, clear the DTCs. 2. Road test the vehicle within the conditions for setting this DTC as specified in the text. Does the scan tool indicate that this diagnostic has run and passed? Go to Step 12 Go to Step 2...
Page 194 3A2-83 BLANK BTRA 4 AUTO TRANSMISSION CHANGED BY REXTON SM - 2004.4 EFFECTIVE DATE AFFECTED VIN...
Page 195 3A2-84 Y220_3A2050 DIAGNOSTIC TROUBLE CODE (DTC) P1712 KICKDOWN SWITCH CIRCUIT MALFUNCTION Circuit Description • A history DTC will clear after 40 TCM power-up cycles with a warm transmission (>50°C) and without a fault. The Kickdown Switch is used to signal the TCM that the driver requires kickdown indicating the driver pressed the •...
Page 196 3A2-85 DTC P1712 Kickdown Switch Circult Malfunction Step Action Value(s) Perform a Transmission Control Module (TCM) Go to “TCM Diagnostic System Check. Diagnostic Go to Step 2 System Check” Is the check performed? 1. Install the scan tool. 2. Turn the ignition ON, with the engine OFF. 3.
Page 197 3A2-86 DTC P1712 Kickdown Switch Circult Malfunction (Cont’d) Step Action Value(s) Check for a poor connection at the Kickdown Switch connector and TCM connector and repair the malfunc- tioning terminals as necessary. Go to Step 15 Go to Step 13 Is a repair necessary? Check the resistance between kickdown switch terminal 1 and 2 when pushing the switch.
Page 198 3A2-87 BLANK BTRA 4 AUTO TRANSMISSION CHANGED BY REXTON SM - 2004.4 EFFECTIVE DATE AFFECTED VIN...
Page 199 3A2-88 Y220_3A2010 DIAGNOSTIC TROUBLE CODE (DTC) P1713 PEDAL SIGNAL ERROR Circuit Description Conditions for Clearing the DTC The Controller Area Network (CAN) connects various control • The DTC will clear when the malfunction has not modules by using a twisted pair of wires, to share common occurred for 30 seconds.
Page 200 3A2-89 DTC P1713 Pedal Signal Error Step Action Value(s) Perform a Transmission Control Module (TCM) Go to “TCM Diagnostic System Check. Diagnostic Is the check performed? Go to Step 2 System Check” 1. Install the scan tool. 2. Turn the ignition ON, with the engine OFF. 3.
Page 201 3A2-90 DIAGNOSTIC TROUBLE CODE (DTC) P1714 EEPROM VEHICLE CODE ERROR System Description Action Taken When the DTC Sets The Electrically Erasable Programmable Read-Only • If CAN is detected, OBD N32D VIN is selected. Or Memory (EEPROM) is a permanent memory chip that is If CAN is not detected, P29 STi VIN is selected.
Page 202 3A2-91 DIAGNOSTIC TROUBLE CODE (DTC) P1715 VPS OFFSET ERROR Circuit Description Conditions for Setting the DTC The VPS is used to regulate the clutch and band pres- • DTC P1720 is not set. sures during a shift. The TCM compares TP voltage, engine •...
Page 203 3A2-92 Y220_3A2200 DIAGNOSTIC TABLE CODE (DTC) 1716 THROTTLE NOT LEARNT ERROR Circuit Description Conditions for Clearing the DTC The Controller Area Network (CAN) connects various control • Throttle learns 0 % position. This value must be greater modules by using a twisted pair of wires, to share common than 0.2 V.
Page 204 3A2-93 DTC P1716 Throttle Not Learnt Error Step Action Value(s) Perform a Transmission Control Module (TCM) Go to “TCM Diagnostic System Check. Diagnostic Is the check performed? Go to Step 2 System Check” 1. Install the scan tool. 2. Turn the ignition ON, with the engine OFF. 3.
Page 205 3A2-94 DIAGNOSTIC TROUBLE CODE (DTC) P1717 RAM ERROR Circuit Description • The transmission adopts the third gear LHM strategy of operation, independent of the vehicle speed. The A normal function of the Transmission Control Module operation of TCM under this condition is difficult to (TCM) programming is to perform an internal check that predict.
Page 206 3A2-95 DIAGNOSTIC TROUBLE CODE (DTC) P1718 ROM ERROR Circuit Description Action Taken When the DTC Sets A normal function of the Transmission Control Module • Adopt Limp Home Mode (LHM) (TCM) programming is to perform an internal check that • The transmission adopts the third gear LHM strategy verifies the integrity of the ROM memory allocations.
Page 207 3A2-96 Y220_3A2060 DIAGNOSTIC TROUBLE CODE (DTC) P1719 CAN BUS ERROR Circuit Description Diagnostic Aids The Controller Area Network (CAN) connects various control • Inspect the wiring for poor electrical connections at modules by using a twisted pair of wires, to share common the TCM and ECM connectors.
Page 208 3A2-97 DTC P1719 CAN Bus Error Step Action Value(s) Perform a Transmission Control Module (TCM) Go to “TCM Diagnostic System Check. Diagnostic Go to Step 2 System Check” Is the check performed? 1. Install the scan tool. 2. Turn the ignition ON, with the engine OFF. 3.
Page 209 3A2-98 DIAGNOSTIC TROUBLE CODE (DTC) P1720 EEPROM ERROR System Description Action Taken When the DTC Sets The Electrically Erasable Programmable Read-Only • If CAN is detected, OBD N32D VIN is selected. Or Memory (EEPROM) is a permanent memory chip that is If CAN is not detected, P29 STi VIN is selected.
Page 210 3A2-99 BLANK BTRA 4 AUTO TRANSMISSION CHANGED BY REXTON SM - 2004.4 EFFECTIVE DATE AFFECTED VIN...
Page 211 3A2-100 Y220_3A2060 DIAGNOSTIC TROUBLE CODE (DTC) P1721 THROTTLE SIGNAL ERROR Circuit Description Conditions for Clearing the DTC The Controller Area Network (CAN) connects various control • The DTC will clear if the malfunction is not present for modules by using a twisted pair of wires, to share common 30 seconds.
Page 212 3A2-101 DTC P1721 Throttle Signal Error Step Action Value(s) Perform a Transmission Control Module (TCM) Go to “TCM Diagnostic System Check. Diagnostic Is the check performed? Go to Step 2 System Check” 1. Install the scan tool. 2. Turn the ignition ON, with the engine OFF. 3.
Page 213 3A2-102 Y220_3A2060 DIAGNOSTIC TROUBLE CODE (DTC) P1722 VEHICLE TYPE DETERMINATION ERROR Circuit Description Conditions for Clearing the DTC The Electrically Erasable Programmable Read-Only • The DTC will clear when the malfunction has not Memory (EEPROM) is a permanent memory chip that is occurred after ignition cycle.
Page 214 3A2-103 DTC P1722 Vehicle Type Determination Error Step Action Value(s) Perform a Transmission Control Module (TCM) Go to “TCM Diagnostic System Check. Diagnostic Is the check performed? Go to Step 2 System Check” 1. Install the scan tool. Go to 2.
Page 215 3A2-104 Y220_3A2070 DIAGNOSTIC TROUBLE CODE (DTC) P1733 SOLENOID 1 CIRCUIT OPEN Circuit Description Conditions for Clearing the DTC The solenoid 1 is used to control fluid flow acting on the 1- • The DTC will clear when the malfunction has not 2 shift valve.
Page 216 3A2-105 Test Description • Inspect the wiring for poor electrical connections at the TCM and at the 10-way transmission connector. The number(s) below refer to the step number(s) on the Look for possible bent, backed out, deformed or Diagnostic Table. damaged terminals.
Page 217 3A2-106 DTC P1733 Solenoid 1 Circuit Open (Cont’d) Step Action Value(s) Check the S1 ground circuit for an open and repair as necessary. Is a repair necessary? Go to Step 11 Go to Step 6 Using a Digital Volt Meter (DVM), measure the Go to resistance between S1 terminal A and B.
Page 218 3A2-107 BLANK BTRA 4 AUTO TRANSMISSION CHANGED BY REXTON SM - 2004.4 EFFECTIVE DATE AFFECTED VIN...
Page 219 3A2-108 Y220_3A2070 DIAGNOSTIC TROUBLE CODE (DTC) P1734 SOLENOID 2 CIRCUIT OPEN Circuit Description Conditions for Clearing the DTC The solenoid 2 is used to control fluid flow acting on the 2- • The DTC will clear when the malfunction has not 3 shift valve.
Page 220 3A2-109 Test Description • Inspect the wiring for poor electrical connections at the TCM and at the 10-way transmission connector. The number(s) below refer to the step number(s) on the Look for possible bent, backed out, deformed or Diagnostic Table. damaged terminals.
Page 221 3A2-110 DTC P1734 Solenoid 2 Circuit Open (Cont’d) Step Action Value(s) Check the S2 necessarycircuit for an open and repair as necessary. Is a repair complete? Go to Step 11 Go to Step 6 Using a Digital Volt Meter (DVM), measure the Go to resistance between S2 terminal A and B.
Page 222 3A2-111 BLANK BTRA 4 AUTO TRANSMISSION CHANGED BY REXTON SM - 2004.4 EFFECTIVE DATE AFFECTED VIN...
Page 223 3A2-112 Y220_3A2070 DIAGNOSTIC TROUBLE CODE (DTC) P1735 SOLENOID 3 CIRCUIT OPEN Circuit Description Action Taken When the DTC Sets The solenoid 3 is a normally open ON/OFF type sole-noid • The solenoid 3 is always OFF. that is used in conjunction with the solenoid 4 to control •...
Page 224 3A2-113 Test Description • Typical causes would be an open circuit in the wiring to or within the solenoid, or a short circuit to power in The number(s) below refer to the step number(s) on the the wiring to or within the solenoid. Diagnostic Table.
Page 225 3A2-114 DTC P1735 Solenoid 3 Circuit Open (Cont’d) Step Action Value(s) Replace the S3. Go to Step 11 Is the action necessary? 1. Disconnect the TCM connector B. 2. Check the wiring harness from 10-way transmission connector terminal 3 to TCM terminal B10 for an open or short to positive and repair as necessary.
Page 226 3A2-115 BLANK BTRA 4 AUTO TRANSMISSION CHANGED BY REXTON SM - 2004.4 EFFECTIVE DATE AFFECTED VIN...
Page 227 3A2-116 Y220_3A2070 DIAGNOSTIC TROUBLE CODE (DTC) P1736 SOLENOID 4 CIRCUIT OPEN Circuit Description Action Taken When the DTC Sets The solenoid 4 is a normally open ON/OFF type sole-noid • The solenoid 4 is always OFF. that is used in conjunction with the solenoid 3 to control •...
Page 228 3A2-117 Test Description • Typical causes would be an open circuit in the wiring to or within the solenoid, or a short circuit to power in The number(s) below refer to the step number(s) on the the wiring to or within the solenoid. Diagnostic Table.
Page 229 3A2-118 DTC P1736 Solenoid 4 Circuit Open (Cont’d) Step Action Value(s) Replace the S4. Go to Step 11 Is the action necessary? 1. Disconnect the TCM connector B. 2. Check the wiring harness from 10-way transmission connector terminal 4 to TCM terminal B4 for an open or short to positive and repair as necessary.
Page 230 3A2-119 BLANK BTRA 4 AUTO TRANSMISSION CHANGED BY REXTON SM - 2004.4 EFFECTIVE DATE AFFECTED VIN...
Page 231 3A2-120 Y220_3A2070 DIAGNOSTIC TROUBLE CODE (DTC) P1737 SOLENOID 5 CIRCUIT OPEN Circuit Description Action Taken When the DTC Sets The solenoid 5 is a variable force solenoid that ramps the • Solenoid 5 is disabled (always OFF). pressure during the gear changes and solenoid switching, •...
Page 232 3A2-121 Test Description • Inspect the wiring for poor electrical connections at the TCM and at the 10-way transmission connector. The number(s) below refer to the step number(s) on the Look for possible bent, backed out, deformed or Diagnostic Table. damaged terminals.
Page 233 3A2-122 DTC P1737 Solenoid 5 Circuit Open (Cont’d) Step Action Value(s) Check the wiring harness from 10-way transmission connector terminal 8 to TCM terminal B1 for an open and repair as necessary. Go to Step 11 Go to Step 9 Is a repair necessary? Check for a poor connection at the 10-way transmission connector and TCM connector and repair the...
Page 234 3A2-123 BLANK BTRA 4 AUTO TRANSMISSION CHANGED BY REXTON SM - 2004.4 EFFECTIVE DATE AFFECTED VIN...
Page 235 3A2-124 Y220_3A2070 DIAGNOSTIC TROUBLE CODE (DTC) P1738 SOLENOID 6 CIRCUIT OPEN Circuit Description Conditions for Clearing the DTC The solenoid 6 is a normally open ON/OFF type solenoid • The DTC will clear when the malfunction has not that is used to set the high/ low level of line pressure. occurred after ignition cycle.
Page 236 3A2-125 • Test Description Inspect the wiring for poor electrical connections at the TCM and at the 10-way transmission connector. The number(s) below refer to the step number(s) on the Look for possible bent, backed out, deformed or Diagnostic Table. damaged terminals.
Page 237 3A2-126 DTC P1738 Solenoid 6 Circuit Open (Cont’d) Step Action Value(s) Check for a poor connection at the 10-way transmission connector and TCM connector and repair the malfunctioning terminals as necessary. Go to Step 11 Go to Step 10 Is a repair necessary? 1.
Page 238 3A2-127 BLANK BTRA 4 AUTO TRANSMISSION CHANGED BY REXTON SM - 2004.4 EFFECTIVE DATE AFFECTED VIN...
Page 239 3A2-128 Y220_3A2070 DIAGNOSTIC TROUBLE CODE (DTC) P1739 SOLENOID 7 CIRCUIT OPEN Circuit Description Conditions for Clearing the DTC The solenoid 7 is a normally open ON/OFF type sole-noid • The DTC will clear when the malfunction has not that is used to control the application of the Torque occurred after ignition cycle.
Page 240 3A2-129 • Test Description Inspect the wiring for poor electrical connections at the The number(s) below refer to the step number(s) on the TCM and at the 10-way transmission connector. Look Diagnostic Table. for possible bent, backed out, deformed or damaged 3.
Page 241 3A2-130 DTC P1739 Solenoid 7 Circuit Open (Cont’d) Step Action Value(s) Using a Digital Volt Meter (DVM), measure the Go to resistance between S7 terminal A and B. “Diagnostic 22 ~ 30 Ω Aids” Go to Step 8 Is the resistance within the specified value? Replace the S7.
Page 242 3A2-131 BLANK BTRA 4 AUTO TRANSMISSION CHANGED BY REXTON SM - 2004.4 EFFECTIVE DATE AFFECTED VIN...
Page 243 3A2-132 Y220_3A2070 DIAGNOSTIC TROUBLE CODE (DTC) P1741 SOLENOID 1 CIRCUIT SHORT Circuit Description Conditions for Clearing the DTC The solenoid 1 is used to control fluid flow acting on the 1- • The DTC will clear when the malfunction has not 2 shift valve.
Page 244 3A2-133 Test Description • Inspect the wiring for poor electrical connections at the TCM and at the 10-way transmission connector. The number(s) below refer to the step number(s) on the Look for possible bent, backed out, deformed or Diagnostic Table. damaged terminals.
Page 245 3A2-134 DTC P1741 Solenoid 1 Circuit Short (Cont’d) Step Action Value(s) Repair the short to ground in the wiring harness. Go to Step 11 Is the repair complete? Using a Digital Volt Meter (DVM), measure the Go to resistance between S1 terminal A and B. “Diagnostic 20 ~ 30 Ω...
Page 246 3A2-135 BLANK BTRA 4 AUTO TRANSMISSION CHANGED BY REXTON SM - 2004.4 EFFECTIVE DATE AFFECTED VIN...
Page 247 3A2-136 Y220_3A2070 DIAGNOSTIC TROUBLE CODE (DTC) P1742 SOLENOID 2 CIRCUIT SHORT Circuit Description Conditions for Clearing the DTC • The DTC will clear when the malfunction has not The solenoid 2 is used to control fluid flow acting on the 2- occurred after ignition cycle.
Page 248 3A2-137 Test Description • If diagnosing for a possible intermittent short or open condition, move or massage the wiring harness while The number(s) below refer to the step number(s) on the observing test equipment for a change. Diagnostic Table. • Solenoid Logic for Static Gear States 3.
Page 249 3A2-138 DTC P1742 Solenoid 2 Circuit Short (Cont’d) Step Action Value(s) 1. Disconnect the TCM connector B. 2. With a test light connected to B+, probe the wiring harness from 10-way transmission connector terminal 2 to TCM terminal B11. Go to Step 5 Go to Step 9 Does the test light illuminate? Check for a poor connection at the 10-way transmission...
Page 250 3A2-139 BLANK BTRA 4 AUTO TRANSMISSION CHANGED BY REXTON SM - 2004.4 EFFECTIVE DATE AFFECTED VIN...
Page 251 3A2-140 Y220_3A2070 DIAGNOSTIC TROUBLE CODE (DTC) P1743 SOLENOID 3 CIRCUIT SHORT Circuit Description • A history DTC will clear after 40 TCM power-up cycles The solenoid 3 is a normally open ON/OFF type sole-noid with a warm transmission (>50°C) and without a fault. that is used in conjunction with the solenoid 4 to control •...
Page 252 3A2-141 • If diagnosing for a possible intermittent short or open 3. Checks if the S3 circuit in the transmission is mal- condition, move or massage the wiring harness while functioning. observing test equipment for a change. 4. Check cable in the transmission for short to ground. 6.
Page 253 3A2-142 DTC P1743 Solenoid 3 Circuit Short (Cont’d) Step Action Value(s) 1. Turn the ignition OFF. 2. Replace the TCM. Go to Step 11 Is the action complete? 1. Using the scan tool, clear the DTCs. 2. Road test the vehicle within the conditions for setting this DTC as specified in the text.
Page 254 3A2-143 BLANK BTRA 4 AUTO TRANSMISSION CHANGED BY REXTON SM - 2004.4 EFFECTIVE DATE AFFECTED VIN...
Page 255 3A2-144 Y220_3A2070 DIAGNOSTIC TROUBLE CODE (DTC) P1744 SOLENOID 4 CIRCUIT SHORT Circuit Description Conditions for Clearing the DTC The solenoid 4 is a normally open ON/OFF type sole-noid • The DTC will clear when the malfunction has not that is used in conjunction with the solenoid 3 to control occurred after ignition cycle.
Page 256 3A2-145 • Test Description Inspect the wiring for poor electrical connections at the TCM and at the 10-way transmission connector. The number(s) below refer to the step number(s) on the Look for possible bent, backed out, deformed or Diagnostic Table. damaged terminals.
Page 257 3A2-146 DTC P1744 Solenoid 4 Circuit Short (Cont’d) Step Action Value(s) Check for a poor connection at the 10-way transmission connector and TCM connector and repair the malfunctioning terminals as necessary. Go to Step 11 Go to Step 10 Is a repair necessary? 1.
Page 258 3A2-147 BLANK BTRA 4 AUTO TRANSMISSION CHANGED BY REXTON SM - 2004.4 EFFECTIVE DATE AFFECTED VIN...
Page 259 3A2-148 Y220_3A2070 DIAGNOSTIC TROUBLE CODE (DTC) P1745 SOLENOID 5 CIRCUIT SHORT Circuit Description Action Taken When the DTC Sets The solenoid 5 is a variable force solenoid that ramps the • Solenoid 5 is disabled (always OFF) pressure during the gear changes and solenoid switching, •...
Page 260 3A2-149 Test Description • Inspect the wiring for poor electrical connections at the TCM and at the 10-way transmission connector. The number(s) below refer to the step number(s) on the Look for possible bent, backed out, deformed or dam- Diagnostic Table. aged terminals.
Page 261 3A2-150 DTC P1745 Solenoid 5 Circuit Short (Cont’d) Step Action Value(s) Probe the wiring harness from 10-way transmission connector terminal 8 to TCM terminal B1. Go to Step 5 Go to Step 10 Does the test light illuminate? Check for a poor connection at the 10-way transmission connector and TCM connector and repair the malfunctioning terminals as necessary.
Page 262 3A2-151 BLANK BTRA 4 AUTO TRANSMISSION CHANGED BY REXTON SM - 2004.4 EFFECTIVE DATE AFFECTED VIN...
Page 263 3A2-152 Y220_3A2070 DIAGNOSTIC TROUBLE CODE (DTC) P1746 SOLENOID 6 CIRCUIT SHORT Circuit Description Conditions for Clearing the DTC • The solenoid 6 is a normally open ON/OFF type sole-noid The DTC will clear when the malfunction has not that is used to set the high/ low level of line pres-sure. occurred after ignition cycle.
Page 264 3A2-153 • Test Description Inspect the wiring for poor electrical connections at the TCM and at the 10-way transmission connector. The number(s) below refer to the step number(s) on the Look for possible bent, backed out, deformed or Diagnostic Table. damaged terminals.
Page 265 3A2-154 DTC P1746 Solenoid 6 Circuit Short (Cont’d) Step Action Value(s) 1. Disconnect the TCM connector B. 2. With a test light connected to B+, probe the wiring harness from 10-way transmission connector terminal 6 to TCM terminal B12. Go to Step 5 Go to Step 9 Does the test light illuminate? Check for a poor connection at the 10-way transmission...
Page 266 3A2-155 BLANK BTRA 4 AUTO TRANSMISSION CHANGED BY REXTON SM - 2004.4 EFFECTIVE DATE AFFECTED VIN...
Page 267 3A2-156 Y220_3A2070 DIAGNOSTIC TROUBLE CODE (DTC) P1747 SOLENOID 7 CIRCUIT SHORT Circuit Description Conditions for Clearing the DTC • The solenoid 7 is a normally open ON/OFF type sole-noid The DTC will clear when the malfunction has not that is used to control the application of the Torque occurred after ignition cycle.
Page 268 3A2-157 • Test Description Inspect the wiring for poor electrical connections at the TCM and at the 10-way transmission connector. The number(s) below refer to the step number(s) on the Look for possible bent, backed out, deformed or Diagnostic Table. damaged terminals.
Page 269 3A2-158 DTC P1747 Solenoid 7 Circuit Short (Cont’d) Step Action Value(s) 1. Disconnect the TCM connector B. 2. With a test light connected to B+, probe the wiring harness from 10-way transmission connector terminal 7 to TCM terminal B9. Go to Step 5 Go to Step 10 Does the test light illuminate? Check for a poor connection at the 10-way transmission...
Page 270 3A2-159 REPAIR INSTRUCTIONS ON-VEHICLE SERVICE TRANSMISSION Removal and Installation Procedure 1. Disconnect the negative battery cable. 2. Disconnect the connectors from transfer case. 3. Disconnect the speedometer connector from transfer case. 4. Disconnect the inhibitor connector, gear position sensor connector and transmission case connector. Y220_3A2080 5.
Page 271 3A2-160 7. Remove the front propeller shaft bolts from transfer case. Installation Notice Tightening torque 70 ~ 80 Nm (52 ~ 59 lb-ft) Y220_3A2110 8. Remove the transfer case-to-transmission housing bolts and remove the transfer case. Installation Notice Tightening torque 44 Nm (33 lb-ft) 9.
Page 272 3A2-161 12. Remove the service hole cover in the engine block. 13. Put the alignment mark for installation, and remove the six mounting bolts for torque converter from drive plate through the service hole by rotating the engine and remove the torque converter. Installation Notice Tightening torque 42 Nm (31 lb-ft)
Page 273 3A2-162 UNIT REPAIR REBUILD WARNINGS Prior to rebuilding a transmission system, the following warnings are to be noted. • Ensure that, before replacing a transmission the cooler lines are flushed out to remove any debris. This can be done by applying compressed air to the rear cooler line forcing oil and any contaminants out of the front cooler line. •...
Page 274 3A2-163 DISASSEMBLY PROCEDURE Transmission Tools Required 0555-336256 Transmission Bench Cradle 0555-336257 Pump Puller Notice • Remove the inhibitor switch before washing the transmission in solvent or hot wash. • It is assumed that the transmission fluid has been drained when the transmission was removed from the vehicle and that the “special tools”...
Page 275 3A2-164 7. Remove the front servo cover circlip. 8. Remove the front servo cover, piston and spring. Notice The plastic servo block is retained by the piston return spring only. 9. Remove the adaptor housing bolts and adaptor housing. Y220_3A2520 10.
Page 276 3A2-165 15. Remove the two centre support retaining bolts using a T50 Torx bit. 16. Remove the centre support retaining circlip. Notice Do not hammer the output shaft to remove the centre support as this will cause permanent damage to the thrust bearing surfaces.
Page 277 3A2-166 5. Using cross shaft pin remover/installer (detent le-ver) 0555-336258, press the pin from the cross shaft and withdraw the shaft from the case. 6. Remove the cross shaft pin and spring. 7. Remove the manual valve lever and the park rod. Y220_3A2600 8.
Page 278 3A2-167 18. To remove the park rod lever: Remove the circlip from the inner end of the pivot shaft and tap the outer end of the shaft until it moves free from the case, then using a wide shallow tapered drift as a wedge, drive the pin out from the inside of the case and remove the lever and spring.
Page 279 3A2-168 9. Invert the clutch cylinder and remove the C4 clutch sleeve, clutch plates and the two wave washers. The 3-4 one way clutch is located between the C2 and C4 clutch hubs, and the hubs may be separated by rotating one hub clockwise and withdrawing it from the other.
Page 280 3A2-169 4. Mount the clutch assembly on clutch spring compressor 0555-336259 and compress the piston return spring. 5. Remove the circlip and release the spring. 6. Remove the tool, circlip, keeper and spring. Notice Make sure that the spring keeper has not been caught in the circlip groove, and that all spring pressure has been released, before removing the tool.
Page 281 3A2-170 Pump Notice The following valves are housed in the pump cover: • Solenoid 7 • Converter clutch control valve • Converter clutch regulator valve • Primary regulator valve 1. Remove the wiring loom retainer plate and remove solenoid 7 with a T30 Torx bit. 2.
Page 282 3A2-171 7. Depress the plug inward and remove the retaining pin for each of the three valves. Notice Some of the valves and plugs are preloaded by springs and may unexpectedly fall out of the cover when the pins are removed. 8.
Page 283 3A2-172 7. Lift the separator plate and gaskets from the upper valve body. 8. Remove the five nylon check balls exposed in the valve body. 9. Remove the retaining plate, plug, spring and re-verse lockout valve. Y220_3A2840 10. Remove the filter (1) and the large nylon check ball (2) from the lower valve body.
Page 284 3A2-173 ASSEMBLY PROCEDURE Transmission Tools Required 0555-336256 Transmission Bench Cradle 0555-336258 Cross Shaft Pin Remover/Installer (Detent Lever) 0555-336262 Cross Shaft Seal Installer 0555-336263 Cross Shaft bullet 0555-336265 Cross Shaft Pin Remover/Installer (Inhibitor Switch) Notice • The transmission is assembled in modular fashion and details of assembly for each module are given under the appropriate subject.
Page 285 3A2-174 4. Install the rear servo lever and pivot pin. Notice The lever must pivot freely on its pin. Y220_3A2890 5. Assemble the park rod lever, complete with the return spring and pivot pin, applying a small amount of sealant to the outer end of the pivot pin.
Page 286 3A2-175 11. Poition the manual valve detent lever, aligning it with the cross-shaft bore in the case. 12. Push the shaft through the detent lever until it starts in the detent lever side of the case. Y220_3A2920 13. Install the detent lever drive pin in the shaft using cross shaft pin remover/installer (detent lever) 0555-336258 with the adaptor over the pin.
Page 287 3A2-176 19. Position the wiring loom and locate the solenoid 7 contact and terminal in the pump mounting flange at the front of the case. The solenoid 7 wire is routed under the park rod and cross shaft in the case. Y220_3A2940 20.
Page 288 3A2-177 Rear Band Assembly 1. Check the rear band for any cracks or damage along the lining and metal backing. 2. Install the reaction anchor strut into the main case, without shims. 3. Carefully install the rear band into the transmission case and ensure that it is properly fitted in the case.
Page 289 3A2-178 Planet Carrier Assembly and Centre Support 1. Check the carrier and planet assembly for any damage or irregularity and ensure that all pinions rotate freely and that the pinion end float is within 0.10 mm ~ 0.50 Y220_3A20A0 2. Install the One Way Clutch (OWC) retainer (1) to the planet carrier with the inner edge pointing down-wards.
Page 290 3A2-179 Adaptor Housing Assembly 1. Install a new seal to the adaptor housing. 2. Position a new gasket onto the adaptor housing. Notice Do not use petroleum jelly to hold the gasket in position. 3. Apply additional Loctite 202 or equivalent as required to the adapter housing bolts.
Page 291 3A2-180 7. Compress the servo cover and fit the servo cover retaining circlip, aligning the gap with the pan rail, and ensuring that it is completely seated in its groove. Notice Ensure that the front servo snap ring is installed correctly.
Page 292 3A2-181 C2/C4 Clutch Assembly Tools Required 0555-336259 Clutch Spring Compressor 0555-336260 Clutch Pack Clearance Kit Notice • Check pistons for cracks. • Do not mix the clutch piston return springs. • Ensure that the snap rings are fitted correctly. 1. Check the feed orifices in the cylinder bore are clear of obstructions.
Page 293 3A2-182 11. Assemble the piston return spring to the piston, and fit the spring retainer over the spring. 12. Using 0555-336259 clutch spring compressor, compress the spring sufficiently to enable the installation of the retaining circlip ensuring that the circlip is firmly seated in its groove, then remove the tool.
Page 294 3A2-183 21. Holding the cylinder horizontal, install the sleeve and clutch plate assembly into the cylinder, with the crest of one wave of the washer in line with one of the holes in the outside of the cylinder, until the sleeve contacts the C2 wave washer.
Page 295 3A2-184 26. Check the clutch pack clearance using only the weight from 0555-336260 clutch pack clearance kit. Notice With the clutch pack supporting a 2 kgweight, the dimension from the C3 clutch hub locating step to the friction plate is to be between 0.80 ~ 1.05 mm. 27.
Page 296 3A2-185 C3 Clutch and Reverse Sun Gear Assembly Tools Required 0555-336259 Clutch Spring Compressor 0555-336260 Clutch Pack Clearance Kit 1. Check the orifices in the cylinder are clear of obstructions. 2. Check the C3 cylinder bush outside diameter and the centre support inside diameter are in good condition and not damaged.
Page 297 3A2-186 11. Assemble the clutch plates and discs into the cylinder in the following sequence : • Steel plate • Friction disc • Steel plate • Steel plate (0574-000013, `014, `015, `016, `019, `022), or Friction disc (0574-000012, `017) • Steel plate (selective) •...
Page 298 3A2-187 Forward Sun Gear and C3 Clutch Pack Assembly 1. Fit the No.7 needle bearing assembly over the forward sun gear, ensuring that the thrust washer is between the bearing and the sun gear. 2. Lubricate the lipped thrust plate with petroleum jelly and fit the thrust plate onto the reverse sun gear.
Page 299 3A2-188 C1 Clutch Overdrive Shaft and Input Shaft Assembly Tools Required 0555-336260 Clutch Pack Clearance Kit Notice • Ensure that the snap rings are fitted correctly. • Check pistons for cracks, especially the C1 piston. • Do not mix clutch piston return springs. •...
Page 300 3A2-189 4. Check the clutch pack clearance using 0555-336260 clutch pack clearance kit. 5. Use selective plates to achieve the correct specifi-cation. Notice With the clutch pack supporting a 2 kg weight, the dimension from the input shaft locating stop to the friction disc must be 0.70 ~ 0.90 mm.
Page 301 3A2-190 13. Assemble the C1/C2/C4 clutch assembly to the C3 clutch and sun gear assembly. 14. Install this assembly in the transmission case. Y220_3A21B0 Pump Cover and Converter Support Notice • Do not wash the nose of solenoids in solvent. •...
Page 302 3A2-191 7. Ensure that the pump cover cavities, ports and holes are clean and free of any obstruction. 8. Lubricate all loose parts with automatic transmission fluid prior to assembly. Y220_3A21D0 9. Assemble the primary regulator valve, spring and plunger to the pump cover, ensuring that the regulator valve slides freely, then fit the regulator valve plug and “O”...
Page 303 3A2-192 13. Install the converter clutch control valve, spring, plug, and “O” ring. 14. Install the retaining pin. Y220_3A21H0 15. Install the converter release check ball and spring. 16. Install the gasket on the pump cover. Y220_3A21J0 17. Install the cover plate, solenoid 7 with the retainer and the solenoid wiring retainer to the pump cover, ensuring that the periphery of the cover plate is flush with the periphery of the pump cover.
Page 304 3A2-193 20. Assemble the pump to the pump cover. 21. Tighten all bolts and the crescent screw finger tight, ensuring that the pump is flush against the pump cover. Tighten the bolts and the screw to specification in the order. (A-F) Installation Notice Bolt (A-E): 24 ~ 27 Nm (18 ~ 20 lb-ft) Tightening...
Page 305 3A2-194 Valve Body Notice • Do not wash the nose of solenoids in solvent. • Be aware of ball positions in the upper valve body. • Be aware of 1-2 and 3-4 shift valve positions, they can be swapped. • Check the 4-3 sequence valve and spring orientation. •...
Page 306 3A2-195 4. Install the solenoid 5 damper guide and spring, piston and retaining pin. Y220_3A2870 5. Install the 4-3 sequence valve, spring, plug and retaining plate. Y220_3A2860 6. Install the 1-2 shift valve, plug and retaining pin. Y220_3A21Q0 7. Install the 2-3 shift valve and retaining pin. Y220_3A21R0 BTRA 4 AUTO TRANSMISSION CHANGED BY...
Page 307 3A2-196 8. Install the 3-4 shift valve and retaining pin. Y220_3A21S0 9. Install the Clutch Apply Regulator (CAR) valve, springs, plunger and retaining pin. Y220_3A21T0 10. Install the solenoid supply valve, spring and retaining plate. Notice This aluminum valve is easily damaged. 11.
Page 308 3A2-197 16. Install the reverse lockout valve, spring, plug and retaining plate. Ensure that the valve is correctly oriented. Y220_3A21V0 17. Position the five nylon ball checks in the upper valve body. 18. Fit the upper valve body gasket. Install the separa-tor plate over the upper valve body.
Page 309 3A2-198 21. Install solenoid 5. Ensure that the solenoid is pushed firmly into the valve body by the retainer and that the screw is tightened to specification. Installation Notice Tightening torque 8 ~ 12 Nm (71 ~ 106 lb-in) Y220_3A21W0 22.
Page 310 3A2-199 25. Check the alignment of the detent roller and the manual lever quadrant. 26. Connect the solenoid wiring as detailed below: Solenoid 1 - red Solenoid 2 - bIue Solenoid 3 - yellow Solenoid 4 - orange Solenoid 5 - green Solenoid 6 - violet Notice All hardware must be correctly installed and torqued...
Page 311 3A2-200 6. Fit the oil pan assembly to the transmission case and tighten the securing bolts to specification and sequence Do not over torque. Installation Notice Tightening torque 4 ~ 6 Nm (35 ~ 53 lb-in) Y220_3A22C0 Torque Converter and Housing Assembly 1.
Page 312 3A2-201 FRONT AND REAR BAND ADJUSTMENT Front Band Setting Procedure Y220_3A22E0 1. Measure the projection of the front servo push rod Notice from the transmission case dimension ’A’. A minimum of one shim is required at all times - a. Apply air at 650/700 kPa to the front servo apply minimum shim size is 1 mm.
Page 313 3A2-202 Rear Band Setting Procedure Y220_3A22F0 1. Measure distance “A” from the rear servo piston to Notice the inner face of the transmission case using vernier A minimum of one shim is required at all times - calipers. minimum shim size is 1 mm. The thickness of available a.
Page 314 3A2-203 Y220_3A22G0 BTRA 4 AUTO TRANSMISSION CHANGED BY REXTON SM - 2004.4 EFFECTIVE DATE AFFECTED VIN...
Page 315 3A2-204 GEAR SHIFT CONTROL LEVER Disassembly and Assembly Procedure 1. Disconnect the negative battery cable. 2. Remove the gear shift control lever assembly. Refer to Section Interior Trim. 3. Remove the gear shift control lever knob. 4. Separate the upper and middle housing from the gear shift control lever assembly by unlocking the lock.
Page 316 3A2-205 KICKDOWN SWITCH 1. Separate the Kickdown Switch from the Kickdown Switch bracket by pushing the lock. 2. Disconnect the Kickdown Switch connector. 3. Installation should follow the removal procedure in the reverse order. Y220_3A25S0 TRANSMISSION CONTROL MODULE Removal and Installation Procedure 1.
Page 317 3A2-206 SPECIFICATIONS GENERAL SPECIFICATION Model Part Numbers and Applications SYMC P/NO Transmission Engine Version Torque Converter 36100-05443 0574-000013 179K 36100-05433 0574-000012 150K 36100-05413 0574-000014 662LA 150K Model Specifications Application Descriprtion Torque Converter Mean Diameter of Fluid Circuit Description 260 mm (10.2 in.) Maximum Torque Multiplication 2.0 : 1 Gear Ratios...
Page 318 3A2-207 Clutch Pack Details 0574-000012 0574-000013 (14) Composition Steel Composition Steel Composition Steel Composition Steel Model Part Numbers and Applications E23 Gasoline Engine SHIFT (km/h) THROTTLE MODE OPENING UNL3 LCK3 UNL4 LCK4 10.1 19.3 36.4 20.8 50.7 79.1 71.7 79.1 10.1 19.3 36.4...
Page 319 3A2-208 E32 Gasoline Engine SHIFT (km/h) THROTTLE MODE OPENING UNL3 LCK3 UNL4 LCK4 11.7 20.2 39.5 24.6 10.2 10.5 37.4 81.9 73.1 81.9 15 % 11.7 22.8 39.5 24.6 10.2 10.5 37.4 81.9 73.1 81.9 25 % 13.3 30.4 67.3 32.2 14.6 10.5...
Page 320 3A2-209 662LA Diesel Engine SHIFT (km/h) THROTTLE MODE OPENING UNL3 LCK3 UNL4 LCK4 11.4 20.4 35.4 26.7 47.6 76.2 72.1 76.2 25 % 11.4 20.4 35.4 27.2 47.6 76.2 72.1 76.2 40 % 12.2 25.4 40.8 29.9 13.6 47.6 76.2 72.1 76.2 60 %...
Page 321 3A2-210 FASTENER TIGHTENING SPECIFICATIONS Application Lb-Ft Lb-Ft 22 ~ 26 Adaptor Housing to Case Bolts 30 ~ 35 Cam Plate to Case (Parking Pawl) Screws 12 ~ 16 16 ~ 22 Centre Support to Case Bolts 15 ~ 20 20 ~ 27 15 ~ 16 Detent Spring Screw 20 ~ 22...
Page 322 3A2-211 SCHEMATIC AND ROUTING DIAGRAMS TCU WIRING DIAGRAM (GASOLINE ENGINE-1 OF 2) Y220_3A2210 BTRA 4 AUTO TRANSMISSION CHANGED BY REXTON SM - 2004.4 EFFECTIVE DATE AFFECTED VIN...
Page 323 3A2-212 TCU WIRING DIAGRAM (GASOLINE ENGINE-2 OF 2) Y220_3A2220 BTRA 4 AUTO TRANSMISSION CHANGED BY EFFECTIVE DATE REXTON SM - 2004.4 AFFECTED VIN...
Page 324 3A2-213 TCU WIRING DIAGRAM (DIESEL ENGINE-1 OF 2) Y220_3A2230 BTRA 4 AUTO TRANSMISSION CHANGED BY REXTON SM - 2004.4 EFFECTIVE DATE AFFECTED VIN...
Page 325 3A2-214 TCU WIRING DIAGRAM (DIESEL ENGINE-2 OF 2) Y220_3A2240 BTRA 4 AUTO TRANSMISSION CHANGED BY EFFECTIVE DATE REXTON SM - 2004.4 AFFECTED VIN...
Page 326 3A2-215 CONNECTOR END VIEW Y220_3A25O0 BTRA 4 AUTO TRANSMISSION CHANGED BY REXTON SM - 2004.4 EFFECTIVE DATE AFFECTED VIN...
Page 327 3A2-216 SPECIAL TOOLS AND EQUIPMENT Name and Part Number 0555 - 336256 0555 - 336257 Transmission Bench Cradle Pump Puller Y220_3A22P0 Y220_3A22Q0 0555 - 336258 0555 - 336259 Cross Shaft Pin Remover/Installer Clutch Spring Compressor (Detent Lever) Y220_3A22R0 Y220_3A22S0 0555 - 336260 0555 - 336261 Clutch Pack Clearance Kit Cross Shaft Seal Remover...
Page 328 3A2-217 Name and Part Number 0555 - 336265 0555 - 336266 Cross Shaft Pin Remover / Installer Adaptor Housing Seal Installer (Inhibitor Switch) Y220_3A22X0 Y220_3A22Y0 0555 - 336267 0555 - 336268 Pump Alignment Tool Pump Seal Installer Y220_3A22Z0 Y220_3A23A0 0555 - 336269 0555 - 336270 End Float Measuring Adaptor End Float Measuring Shaft...
Page 329 MEMO ..................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................
Page 330 3B-1 SECTION 3B TSM54/52 MANUAL TRANSMISSION Table of Contents GENERAL INFORMATION ..........3B-3 Overview ..............3B-3 Specifications ............. 3B-4 System components ..........3B-5 Shifting mechanism ..........3B-17 Diagnostic information and procedures ....3B-25 Circuit diagram (backup lamp) ........ 3B-28 ON-VEHICLE SERVICE ..........3B-29 Oil check/change .............
Page 331 3B-3 GENERAL INFORMATION OVERVIEW Features Y220_03B003 1. All gears use the helical type and high strength materials. Note The helical type gear prevents the axial gear missing and provides less noise. 2. The synchronizing devices are installed in 1/2, 3/4, 5/R gears. To prevent the double engagement, the independent interlock devices are installed.
Page 332 3B-4 SPECIFICATIONS General Specifications Description IDI ENGINE DI ENGINE Length (mm) 4WD: 628.3, 2WD: 672 4WD: 625, 2WD: 672 Distance between shafts (mm) Input torque (kg m) 32 (320 Nm) 34.7 (340 Nm) Transmission control type Semi-remote Weight (kg) - not including transmission fluid (kg m) 4WD: 44, 2WD: 45 Gear ratio/Gear teeth 1st gear...
Page 333 3B-5 SYSTEM COMPONENTS Gear Combinations 1/2 shift fork 5/R shift fork 3/4 shift fork 1st gear 2nd gear Input gear Input shaft Output shaft 5th gear 3rd gear 4th gear Counter shaft Y220_03B006 Shift Fork and Rail Combinations Speedometer gear (2WD) Transmission adaptor Interlock plate Reverse lock plate...
Page 334 3B-6 Sectional View DI Engine equipped vehicle - 4WD Y220_03B008 TSM54/52 MANUAL TRANSMISSION CHANGED BY EFFECTIVE DATE REXTON SM - 2004.4 AFFECTED VIN...
Page 335 3B-7 1. Transmission front housing 38. Reverse idler gear 2. Input shaft oil seal 39. Reverse idler spacer 3. Front cover 40. Reverse idler bracket 4. Hexagon flange bolt (17 ~ 26 Nm) 41. Retainer ring 5. Oil drain plug 42.
Page 336 3B-8 IDI Engine equipped vehicle - 4WD Y220_03B008B TSM54/52 MANUAL TRANSMISSION CHANGED BY EFFECTIVE DATE REXTON SM - 2004.4 AFFECTED VIN...
Page 337 3B-9 1. Transmission front housing 38. Reverse idler gear 2. Input shaft oil seal 39. Reverse idler spacer 3. Front cover 40. Reverse idler bracket 4. Hexagon flange bolt (17~26 Nm) 41. Retainer ring 5. Oil drain plug 42. Reverse lock nut 6.
Page 338 3B-10 IDI Engine equipped vehicle - 2WD Y220_03B008C TSM54/52 MANUAL TRANSMISSION CHANGED BY EFFECTIVE DATE REXTON SM - 2004.4 AFFECTED VIN...
Page 339 3B-11 1. Transmission front housing 39. Reverse idler spacer 2. Input shaft oil seal 40. Reverse idler bracket 3. Front cover 41. Retainer ring 4. Hexagon flange bolt (17 ~ 26 Nm) 42. Reverse lock nut 5. Oil drain plug 43.
Page 340 3B-12 Front View and Rear View Front view Rear view Y220_03B009 1. Oil filler plug 8. Interlock bolt 16. Reverse idler assembly (tightening torque: 40 ~ 50 Nm) (tightening torque: 40 ~ 50 Nm) 17. Spring pin (6 x 25) 2.
Page 341 3B-13 Cross Sectional Diagram of Major Components Shift rail and 5/R gear 1/2 shift rail 5/R shift rail 3/4 shift rail Offset lever 5. Apply Loctite DRI LOC 200 10. Apply Loctite 5900 A. Apply Long-term grease MoS2 Y220_03B010 1. Reverse lock spring 7.
Page 342 3B-14 Power Flows 1st gear Counter shaft Reverse gear gear gear gear gear gear 2nd gear Reverse gear gear gear gear gear gear Y220_03B011 TSM54/52 MANUAL TRANSMISSION CHANGED BY EFFECTIVE DATE REXTON SM - 2004.4 AFFECTED VIN...
Page 343 3B-15 Power Flows (Cont’d) 3rd gear Reverse gear gear gear gear gear gear 4th gear Reverse gear gear gear gear gear gear Y220_03B012 TSM54/52 MANUAL TRANSMISSION CHANGED BY REXTON SM - 2004.4 EFFECTIVE DATE AFFECTED VIN...
Page 344 3B-16 Power Flows (Cont’d) 5th gear Reverse gear gear gear gear gear gear Reverse gear Reverse gear Reverse gear gear gear gear idler gear gear Y220_03B013 TSM54/52 MANUAL TRANSMISSION CHANGED BY EFFECTIVE DATE REXTON SM - 2004.4 AFFECTED VIN...
Page 345 3B-17 SHIFTING MECHANISM Interlock System Interlock system prevents the gears from meshing over two sets. Interlock bolt Interlock plate Inner shift lever (3/4 & 5/R lock) (1/2 & 5/R lock) (1/2 & 3/4 lock) Y220_03B014 Reverse Interlock System Reverse interlock system prevents the gear from shifting to reverse driving position while driving forward. Neutral 5/R select 5/R shift...
Page 346 3B-18 Offset Lever and Rolling Plunger To make the next shift easier, the offset lever applies a reaction force to shift lever toward center position of gear selection gate after a gear has been selected. Y220_03B016 1. Offset lever 3. Shift shaft 2.
Page 347 3B-19 1. Shift check device It determines the shift fork position (N or each gear) and Detent pin gives a detent movement to notice a shift lever seating when operating the shift lever. Top cover Also, it prevent the selected gear from getting out of its meshed position.
Page 348 3B-20 Synchronizer Composition It consists of synchronizer hub, sleeve, ring, key and spring (1/2, 5/R, and 3/4 synchronizer are different from each other). - 3/4 and 5/R shift: Single cone type - 1/2 shift: Double cone type - Improving the capacity to bigger engine torque of 1/2 shift (added synchronizer inner cone and middle cone) Single cone type Double cone type...
Page 349 3B-21 Synchronizer element A cone or sleeve that slides to and fro on the transmission main shaft and makes the gears rotate at the same speed to prevent clash when the gears are about to mesh. Whenever a vehicle is rolling, the transmission main shaft is turning and the clutch gear is spinning.
Page 350 3B-22 Bearing The needle bearings are introduced to each gear and the taper roller bearings are used for input and counter shaft in transmission housing. Taper roller bearing Needle bearing Y220_03B024 1. Taper roller bearing 3. Needle bearing for reverse gear (input shaft, counter shaft and output shaft) (with cut out area) 2.
Page 351 3B-23 Thrust Ring (Washer) When the driving force from engine is transmitted to the output shaft of transmission, each shaft and gear assembly receives the axial force and this force acts as a resistance to rotating gears. Input shaft Thrust ring 1 Thrust washer Output shaft synchronizer...
Page 352 3B-24 Y220_03B029 Y220_03B028 1. Oil filler plug 2. Air vent Installation Notice Sealant on oil drain screw during installation: Loctite DRI LOC 200 Tightening torque: 40 ~ 50 Nm TSM54/52 MANUAL TRANSMISSION CHANGED BY EFFECTIVE DATE REXTON SM - 2004.4 AFFECTED VIN...
Page 353 3B-25 DIAGNOSTIC INFORMATION AND PROCEDURES Trouble Diagnosis Symptom Cause Action Will not shift Control lever assembly broken or Replace control lever and housing (control lever moves) damaged. assembly. Damaged offset lever, shift fork, selector Remove extension, adapter or case cover. place or selector arm.
Page 354 3B-26 Symptom Cause Action Transmission locked in Worn or damaged synchronizer. Check worn or damaged synchronizer one gear parts and replace if necessary. Worn or damaged gears. Check worn or damaged gears and replace if necessary. Transmission noise Improper or low transmission oil. Add or drain and replace with proper oil.
Page 355 3B-27 Diagnosis table Applicatio 1 Shift Hop-out 2 Shift Gear Crash 3 Shift Block-out 4 Hard Shift 5 Noise in Reverse Gear 6 Noise in 5th Gear 7 Noise in 4th Gear 8 Noise in 3rd Gear 9 Noise in 2nd Gear 10 Noise in 1st Gear 11 Noise in All Speeds 12 Leak at Transmission Rear Part...
Page 356 3B-28 CIRCUIT DIAGRAM (BACKUP LAMP) Y220_03B030 TSM54/52 MANUAL TRANSMISSION CHANGED BY EFFECTIVE DATE REXTON SM - 2004.4 AFFECTED VIN...
Page 357 3B-29 ON-VEHICLE SERVICE OIL CHECK/CHANGE Notice Do not check or change the oil Immediately after driving off. It may cause serious hurt. Place the vehicle on the flat and even ground and stop the engine. After 5 minutes, check the oil level. 1.
Page 358 3B-30 REMOVAL AND INSTALLATION Y220_03B033 1. Manual transmission assembly 4. Transfer case 2. Transmission housing mounting bolt 5. Transmission insulator 3. Air bleed hose 6. Center cross member TSM54/52 MANUAL TRANSMISSION CHANGED BY EFFECTIVE DATE REXTON SM - 2004.4 AFFECTED VIN...
Page 359 3B-31 Removal and Installation 1. Disconnect the negative battery cable. 2. Remove the shift lever knob. Unscrew the screws and remove the console box cover. Y220_03B034 3. Unscrew the nuts and remove the shift lever. Installation Notice Tightening torque 70 ~ 90 Nm 4.
Page 360 3B-32 7. Unscrew the bolts and detach the propeller shaft connected to transfer case output shaft. Compress the propeller shaft and bind to torsion bar not to disturb the operation. Installation Notice Tightening torque 80 ~ 90 Nm Y220_03B040 8. Support the underbody of transmission not to deflect it and unscrew the bolts and cross nuts and remove the cross member.
Page 361 3B-33 12. Unscrew the bolts and remove the transmission mounting insulator. Installation Notice Tightening torque 25 Nm Y220_03B045 13. Unscrew the transfer case mounting bolts. Y220_03B046 14. Remove the transfer case with a hydraulic jack. Be careful not to spill the oil. Y220_03B047 15.
Page 362 3B-34 16. Securely support the transmission with a hydraulic jack. Unscrew the mounting bolts and remove the transmission. Installation Notice Tightening torque 75 ~ 85 Nm 17. Install in the reverse order of removal. Y220_03B049 TSM54/52 MANUAL TRANSMISSION CHANGED BY EFFECTIVE DATE REXTON SM - 2004.4 AFFECTED VIN...
Page 363 3B-35 Inspection Before Installation Check the components for wear and damage before installation. 1. Check the release bearing for abnormal wear and replace if needed. 2. Check the conditions of pressure plate. Notice Check each component and replace if needed. Y220_03B050 3.
Page 364 3B-36 DISASSEMBLY AND REASSEMBLY MANUAL TRANSMISSION ASSEMBLY System Layout Y220_03B055 TSM54/52 MANUAL TRANSMISSION CHANGED BY EFFECTIVE DATE REXTON SM - 2004.4 AFFECTED VIN...
Page 365 3B-37 Disassembly 1. Unscrew the transmission oil drain plug (1) and drain the oil. Place the removed transmission on the work bench. Note This manual is described based on 4WD manual transmission because the service operation (disassembly and reassembly) of 4WD nad 2WD manual transmission is same.
Page 366 3B-38 5. Remove the bolts from the extension housing. Y220_03B060 6. Remove the extension housing with a special tool. Notice Remove the offset lever and rolling plunger with the extension housing. Be careful not to drop them. Y220_03B061 7. Remove the rear ball bearing with a puller and remove the speedometer driven gear.
Page 367 3B-39 8-1. Pull the counter gear (5th gear) retainer ring out from the ring groove with a ring pliers. Y220_03B064 Notice Be careful not to stiffen the retainer ring. Y220_03B065 9. Spread the retainer ring and remove the counter 5th gear with a puller.
Page 368 3B-40 11. Remove the 5th gear retainer ring with a ring pliers. Y220_03B068 12. Remove the thrust washer from the shaft. Y220_03B069 13. Remove the 5th gear and pull out the spring pin. Notice Be careful not to lose or mix the spring pins. Y220_03B072 14.
Page 369 3B-41 15. Remove the 5th gear synchronizer ring. Notice Store at a safe place not to be mixed with other synchronizer rings. Y220_03B074 16. Remove 5/R gear retainer ring from the shaft with a ring pliers. Notice Store the ring with the relevant gear to prevent incorrect installation.
Page 370 3B-42 19. Remove the counter reverse gear needle bearing. Notice Store the needle bearing with the relevant gear. Y220_03B078 20. Remove the interlock bolt. Y220_03B079 21. Remove the transmission adaptor from the transmission housing. Notice Be careful not to damage the adaptor mating surface. Y220_03B080 22.
Page 371 3B-43 23. Remove the main and counter gear assembly. • Pull out the pins from 5/R and 1/2 shift rails and remove the shift rails through rear section of adaptor. • Pull out the locking pins from shift forks. Y220_03B081 24.
Page 372 3B-44 27. Remove the 3/4 gear synchronizer hub and single synchronizer sleeve and 3rd gear with a special tool. Pull out the needle bearing. Y220_03B085 28. Loose the 1/2 gear and hub and double synchronizer sleeve with a press. Y220_03B086 29.
Page 373 3B-45 31. Remove the inner race and 1st gear from 1st gear, and remove the needle bearing from the shaft. Notice Store the disassembled gears by relevant components. Y220_03B089 32. Remove the synchronizer inner intermediate cone and outer ring in 1st gear side. Synchronizer Synchronizer Synchronizer...
Page 374 3B-46 35. Remove the 2nd gear and needle bearing. Y220_03B094 36. Remove the oil seal from the extension housing. Y220_03B094A TSM54/52 MANUAL TRANSMISSION CHANGED BY EFFECTIVE DATE REXTON SM - 2004.4 AFFECTED VIN...
Page 375 3B-47 Inspection Before Reassembly 1. Clean all the disassembled components with solvent and dry them with compressed air. Check the components for crack, wear and damage. • Case, extension housing, shift lever • Input bearing retainer • Counter shaft rear bearing retainer 2.
Page 376 3B-48 • Hub and sleeve • 1/2 shift fork, pads, synchronizer sleeve Y220_03B099 • 3/4 shift fork, pads, synchronizer sleeve • 5th gear shift rail/fork, pads, synchronizer sleeve • Reverse fork and reverse idler gear sleeve Y220_03B099A 6. Check the following components for excessive wear: •...
Page 377 3B-49 9. Check the conditions of each synchronizer sleeve and hub. • Engagement of hub and sleeve • Wear on cone clutch surface in blocking ring (brass) engaging the gears Y220_03B104 10. Measure the clearance between blocking ring and speed gear.
Page 378 3B-50 Reassembly 1. Install the 2nd gear needle bearing. Notice The 1st/2nd/3rd gear needle bearings have one bearing row and the sizes of them are same. The reverse needle bearing has two bearing rows. The 5th needle bearing is smaller than others and consists of two bearings.
Page 379 3B-51 4. Install the 1/2 synchronizer hub and double synchronizer sleeve into the output shaft by using a press. Notice Make sure that the hub groove faces to 2nd gear. Align the synchronizer key and the synchronizer ring groove in 2nd gear. Y220_03B110 5.
Page 380 3B-52 8. Install the 1st gear inner race by using a press. Notice The 1st inner race doesn’t have a step at edge. Y220_03B114 9. Install the main taper roller bearing by using a press. Y220_03B115 10. Install the reverse fear inner race by using a press. Notice The reverse gear inner race has a step at edge.
Page 381 3B-53 12. Install the 3rd gear. Y220_03B118 13. Install the synchronizer ring on the 3rd gear. Y220_03B119 14. Insert three keys into 3/4 synchronizer hub and synchronizer sleeve. Install the synchronizer spring in offset so that it should not be missed out. Notice 3/4 gear synchronizer sleeve have a step at edge.
Page 382 3B-54 15. Install the 3/4 gear retainer ring. Notice Adjust the end play between retainer ring and hub to a range of 0.05 to 0.1 mm by using a thickness gauge. Y220_03B121 16. Install the intermediate taper roller bearing by using a press.
Page 383 3B-55 18. To relieve the load to the shaft bearing, insert a special tool. Y220_03B124 19. Place the counter gear on the work bench with the same manner. Y220_03B125 20. Install the transmission adaptor on the input shaft and the counter gear. Y220_03B126 21.
Page 384 3B-56 22. Install the reverse gear in the shaft. Y220_03B128 23. Install the synchronizer ring on the reverse gear. Y220_03B129 24. Insert three keys into 5/R synchronizer hub and synchronizer sleeve. Install the synchronizer spring in offset so that it should not be missed out. Notice Place the groove in hub to face the 5th gear and align the synchronizer key and the synchronizer ring...
Page 385 3B-57 26. Install the counter reverse gear by using a press. Notice Place the counter reverse gear with a longer protrusion facing to the adaptor. Y220_03B132 27. Install the counter reverse spacer. Y220_03B133 28. Install the 5th synchronizer ring. Y220_03B134 29.
Page 386 3B-58 30. Install the 5th gear. Y220_03B136 31. Install the counter 5th gear by using a press. At this time, place it with a longer protrusion facing to the adaptor. Y220_03B137 32. Install the counter 5th gear retainer ring. Y220_03B138 33.
Page 387 3B-59 34. Install the thrust washer (t= 5.0) while aligning the key grooves. Y220_03B140 35. Install the retainer ring. Notice Adjust the end play between retainer ring and hub to a range of 0.08 to 0.22 mm by using a thickness gauge.
Page 388 3B-60 38. Install the inner shift lever and interlock plate in the 3/4 Interlock plate Inner shift lever gear shift rail. Notice The spring pin for locking the inner shift lever is small (6 x 22) and its slot should face to the shaft. Y220_03B144 39.
Page 389 3B-61 42. Install the 1/2 gear shift rail in the transmission adaptor. Y220_03B148 43. Partially engage the 1/2 shift fork to the shift rail. Y220_03B149 44. Install the shift lug on the 1/2 shift rail. Install the reverse lock spring, reverse lock plate and reverse lock bolts. Notice Align the 1/2 gear shift lug and interlock plate mating surface.
Page 390 3B-62 46. Install the 5/R shift lug and 5/R shift fork on the shift rail. Notice Align the 5/R shift lug and the interlock plate surface. Y220_03B152 47. Install the spring pin into the 1/2 shift lug. (intermediate size: t= 6 x 25) Notice Place the spring pin with the pin slot facing to the shaft.
Page 391 3B-63 50. Install the spring pin into the 5/R shift fork. (longer size: t= 6 x 28) Notice Place the spring pin with the pin slot facing to the shaft. Y220_03B156 51. Install the reverse lock plate and reverse lock spring on the 1/2 shift rail.
Page 392 3B-64 53. Apply the sealant to the transmission housing. Notice Sealant: LOCTITE 5900 Y220_03B159 54. Install the gear assembly and the adaptor to the transmission housing. 55. Install the speedometer driven gear on the output shaft and install the ball bearing by using a press. Y220_03B160 56.
Page 393 3B-65 57. Tighten the extension housing bolts. Tightening torque 42 ~ 57 Nm Y220_03B163 58. Insert the offset lever into the 3/4 rail and install the spring pin. (intermediate size: t= 6 x 25) 59. Apply the grease into the offset lever bushing. Y220_03B164 60.
Page 394 3B-66 61. Apply the grease to the top cover and tighten the bolts. Notice Place the gear in the neutral position. Sealant LOCTITE 5900 Tightening torque 17 ~ 50 Nm Y220_03B166 62. Install the TGS bushing. Y220_03B167 TSM54/52 MANUAL TRANSMISSION CHANGED BY EFFECTIVE DATE REXTON SM - 2004.4...
Page 395 3B-67 63. Insert the TGS pin and install the lock washer. Y220_03B168 TSM54/52 MANUAL TRANSMISSION CHANGED BY REXTON SM - 2004.4 EFFECTIVE DATE AFFECTED VIN...
Page 396 3B-68 TOP COVER ASSEMBLY System Layout Y220_03B169 1. Remote shift 14. Bolt 15. Breather hose barb 2. Shift lever 16. Control shift spring 3. Shift inner boot 17. Offset control lever 4. Lining shift socket 5. Control housing arm insulator 18.
Page 397 3B-69 Disassembly and Reassembly 1. Remove the lock washer from the TGS pin in the extension housing and the control arm. Remove the TGS pin. Y220_03B170 2. Remove the TGS pin from the control arm and swing back the control arm. Y220_03B170A TSM54/52 MANUAL TRANSMISSION CHANGED BY...
Page 398 3B-70 3. Lay down the semi-remote lever assembly and remove the top cover bolts. Y220_03B171 4. Remove the lock washer from the shift shaft connection link in the semi-remote lever assembly and pull out the pin. Y220_03B172 5. Remove the lock washer from the shift shaft connection link and pull out the pin.
Page 399 3B-71 6. Remove the retainer ring. 7. Remove the joint pin. Y220_03B174 8. Install in the reverse order. Apply the MoS 2 grease to the shaft and top cover if cleaned them. Y220_03B176 TSM54/52 MANUAL TRANSMISSION CHANGED BY REXTON SM - 2004.4 EFFECTIVE DATE AFFECTED VIN...
Page 400 3B-72 EXTENSION HOUSING ASSEMBLY Disassembly and Reassembly 1. Separate the extension housing. Y220_03B177 2. Unscrew the spring plug and remove the return spring and rolling plunger. Installation Notice Tightening torque 30 ~ 35 Nm Y220_03B178 TSM54/52 MANUAL TRANSMISSION CHANGED BY EFFECTIVE DATE REXTON SM - 2004.4 AFFECTED VIN...
Page 401 3B-73 3. Unscrew the counter screw and remove the offset plate. Installation Notice Tightening torque 4 ~ 6 Nm Y220_03B179 TSM54/52 MANUAL TRANSMISSION CHANGED BY REXTON SM - 2004.4 EFFECTIVE DATE AFFECTED VIN...
Page 402 3B-74 TRANSMISSION ADAPTOR Disassembly and Reassembly 1. Remove the reverse idler retainer ring. Y220_03B180 2. Remove the components as follows and install in the reverse order of removal. • Unscrew the reverse lock nut and idler bracket bolts and remove the bracket and spacer. •...
Page 403 3B-75 INSPECTION/MAINTENANCE SHIM ADJUSTMENT 1. Unscrew the bolts and remove the front fork cover. Notice The shim adjustment is necessary when replacing the housings, counter gear, input shaft and output shaft. Y220_03B183 2. Separate the front fork cover from the housing. Y220_03B183A 3.
Page 404 3B-76 4. Remove the counter spacer. Y220_03B185 5. Prepare the special tools and dial gauge. Y220_03B186 6. Place the transmission with the output shaft facing downward and set the special tool on the counter gear and input shaft. Apply a proper force to the counter gear and input shaft so that the end plays for bearings are maximized.
Page 405 3B-77 8. Set up the dial gauge on the transmission housing surface and put the gauge needle to “0” point. 9. Put the probe end of the gauge on the taper roller bearing outer race in counter gear and measure the end play. * If the measured value is out of the specified range, adjust it by using spacers.
Page 406 3B-78 SPECIAL TOOLS AND EQUIPMENT Name and Part Number Application 661 589 04 62 00 (W 99 31 007 0B) Removal/installation of transmission Transmission fixture Y220_03B194 Y220_03B195 W 99 31 001 1B Removal of pressed in taper roller bearing Bearing puller Y220_03B196 Y220_03B197 W 99 31 002 1B...
Page 407 3B-79 Name and Part Number Application W 99 31 004 1B Assembly of gears and bearings on the shafts Y220_03B202 Y220_03B203 W 99 31 005 2B Measurement of taper roller bearing end play Holder Y220_03B204 Y220_03B205 W 99 31 006 1B Measurement of taper roller bearing end play Dial gauge holder...
Page 408 MEMO ..................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................
Page 409 3C-1 SECTION 3C CLUTCH Table of Contents GENERAL DESCRIPTION AND OPERATION ....3C-3 Overview ..............3C-3 Specifications ............. 3C-4 Diagnostic information and procedures ....3C-5 Cross sectional view of clutch assembly ....3C-6 ON-VEHICLE SERVICE ..........3C-7 Clutch components ............ 3C-7 Bleeding of clutch system ..........
Page 410 3C-3 GENERAL DESCRIPTION AND OPERATION OVERVIEW Driving Elements Operating Elements The driving elements consist of two flat surfaces machined The clutch release system consists of the clutch pedal to a smooth finish. are clutch release cylinder. One of these is the rear face of the engine flywheel and This system directly releases the clutch by using hydrau- the other is the clutch pressure plate.
Page 411 3C-4 SPECIFICATIONS Specifications Description Specification Operating type Hydraulic Clutch pedal Suspended Type Diesel engine equipped vehicle: 158 mm Maximum pedal stroke Gasoline engine equipped vehicle: 150 mm 5 ~ 10 mm Pedal free play Clutch disc Single dry diaphragm Type 240 X 155 X 4.0 mm Dimension of facing 263 cm...
Page 412 3C-5 DIAGNOSTIC INFORMATION AND PROCEDURES Check Possible Cause Action Clutch slips Excessive wear of facing Replace Hard or oily facing Repair or replace Damaged pressure plate or flywheel Replace Damaged or burnt diaphragm spring Replace Clutch pedal free play insufficient Adjust Faulty operation of clutch pedal Repair or replace...
Page 413 3C-6 CROSS SECTIONAL VIEW OF CLUTCH ASSEMBLY Y220_03C004 1. Transmission housing 4. Bolt 2. Clutch disc assembly 5. Washer 3. Clutch disc cover assembly 6. Bolt CLUTCH CHANGED BY EFFECTIVE DATE REXTON SM - 2004.4 AFFECTED VIN...
Page 414 3C-7 ON-VEHICLE SERVICE CLUTCH COMPONENTS Y220_03C005 1. Clutch pedal 7. Clutch housing 2. Clutch master cylinder 8. Concentric slave cylinder cover 3. Clutch hydraulic line 9. Concentric slave cylinder 4. Clutch fluid chamber 10. Clutch cover 5. Clutch fluid hose 11.
Page 415 • This work has to be done by two service persons. • After bleeding, check the clutch system for operation and noise. • Use only Ssangyong genuine clutch fluid, and check the clutch fluid level in reservoir. Clutch fluid SAE J1730 or DOT 3, 4...
Page 416 3C-9 Removal and Installation 1. Unscrew nut and disconnect the clutch fluid hose (1) from adaptor. Simultaneously, disconnect the backup lamp switch (2) connector. Y220_03C014 2. Unscrew the clutch housing bolts and remove the clutch housing with transmission. (refer to Manual Transmission section in this manual) Installation Notice Tightening torque...
Page 417 3C-10 4. Unscrew the bolts and remove the clutch cover, pressure plate and clutch disc. Notice Be careful not to drop the pressure plate and clutch disc. Installation Notice Tightening torque 1.0 ~ 1.6 kgf m Y220_03C011 5. Remove the oil pipe and the adapter from the clutch housing.
Page 418 3C-11 CLUTCH MASTER CYLINDER Removal and Installation 1. Drain the clutch fluid. 2. Pull out the snap pin and clevis pin from the clutch pedal connection. 3. Remove the clutch tube. Installation Notice Tightening torque 15 ~ 18 Nm Notice Y220_03C016 Be careful not to contact the fluid into a painted surface.
Page 419 3C-12 CLUTCH PEDAL Y220_03C019 1. Snap pin ............replace 9. Turnover spring ........apply grease 2. Clevis pin ..........apply grease 10. Bushing ............replace 3. Clutch master cylinder push rod 11. Full stroke stopper contact pad 4. Gasket 12. Interlock switch stopper pad 5.
Page 420 3C-13 Removal and Installation 1. Remove the snap pin from master cylinder push rod and remove the clevis pin from pedal. Y220_03C020 2. Remove the turnover spring. Y220_03C021 3. Unscrew the fulcrum bolt and remove the clutch pedal from bracket Y220_03C022 4.
Page 421 3C-14 5. Unscrew the mounting bolts and remove the clutch pedal bracket. Y220_03C024 Installation notice 1. Install in the reverse order of removal. Adjust pedal Description Tightening Torque stroke after installation. Fulcrum bolt/nut 16 ~ 22 Nm Bracket mounting bolt 8 ~ 18 Nm Notice Stopper bolt...
Page 422 3C-15 Clutch Fluid Pipe Removal and installation 1. Draw out the fluid. 2. Unscrew the bolt and remove the supply pipe from clutch master cylinder. Y220_03C026 3. Unscrew the supply pipe bolt (2) and remove primary oil pipe from clutch fluid chamber. 4.
Page 423 3C-16 INSPECTION PROCEDURE Clutch Disc 1. Clutch cover assembly • Check the diaphragm spring tip for wear and height unevenness. Unevenness limit 0.8 mm • Check the pressure plate surface for wear, crack and discoloration. • Check the strap plate rivet for looseness and replace if necessary.
Page 424 3C-17 4. Pressure plate 1) Check the pressure spring for wear. Notice The excessively worn components should be replaced. Y220_03C031 2) Check the alignment conditions of clutch housing as follows: • Install the magnetic holder on pressure spring. • Alignment check for housing bore A.
Page 425 3C-18 SPECIAL TOOLS AND EQUIPMENT Name and Part Number Application 661 589 00 15 00 (L 99 30 001 0B) Centering the clutch disc Centering pin Y220_03C037 Y220_03C038 601 589 02 40 00 (A 99 10 014 0B) Locking the crankshaft Engine lock Y220_03C035 Y220_03C036...
Page 426 3D-1 SECTION 3D PART TIME - T/C Table of Contents GENERAL INFORMATION ..........3D-3 Overview ..............3D-3 Operation ..............3D-3 Specifications ............. 3D-4 Sectional diagram ............3D-5 TCCU ................. 3D-7 System layout ............. 3D-8 SYSTEM OPERATION ........... 3D-9 Transfer Case Control Unit (TCCU) ......3D-9 POWER FLOW .............
Page 427 3D-3 GENERAL INFORMATION OVERVIEW By using the planetary gear sets, two-gears shift type part time transfer case achieves direct connection when selecting 4WD “HIGH” and 2.48 of reduction gear ratio when selecting 4WD “LOW”. The silent chain in transfer case transfers the output power to front wheels.
Page 428 3D-4 SPECIFICATIONS Description New Part Time T/C Total length 343 mm Mating surface of front flange 40 mm Weight 33.8 kg (without oil) Oil capacity 1.4 L Location Transfer case Major elements Housing Part time & TOD (common) Tightening bolt 11 EA, M8 x 1.25 Input shaft A/T: External spline...
Page 429 3D-5 SECTIONAL DIAGRAM Planetary gear set Oil pump Magnetic clutch Input shaft 4H-4L 2H–4H Shift fork Shift fork (Reduction shift fork) (lockup fork) Shift motor Front output shaft Y220_03D002 PART TIME CHANGED BY REXTON SM - 2004.4 EFFECTIVE DATE AFFECTED VIN...
Page 430 3D-6 Shift Motor When selecting a position in 4WD switch, the shift control unit exactly changes the motor position to 2H, 4H and 4L by the position encoder in control unit that monitors motor position. Function Position A Position B Position C 3 (Brown/ 4 (Violet/White)
Page 431 3D-7 TCCU Y220_03D005 Description TCCU Connector type One integrated connector Number of pins Weight 0.22 kg CAN-BUS Vehicle speed signal CAN communication Lamp CAN communication Clutch signal (M/T) CAN communication Neutral signal (A/T) CAN communication Appearance and Function Pin No. Description Pin No.
Page 432 3D-8 SYSTEM LAYOUT Indicators 4WD switch Output Input Automatic transmission Magnet clutch Oil pump Drive gear Input shaft Speed sensor (4L) Planetary gear set Shift position 2H-4H shift fork Front output shaft Shift motor Y220_03D006 PART TIME CHANGED BY EFFECTIVE DATE REXTON SM - 2004.4 AFFECTED VIN...
Page 433 3D-9 SYSTEM OPERATION TRANSFER CASE CONTROL UNIT (TCCU) 4WD Operation TCCU is located under the driver’s seat and permits the ve- hicle to shift from two-wheel drive to four-wheel drive (and back shift) according to drivers switch operation during driving (For the shifting between 4WD HIGH and 4WD LOW, stop the vehicle).
Page 434 3D-10 Transfer Case Block Diagram Shift motor output (Motor LO-HI) Battery voltage Shift motor output Ignition switch ON/OFF (Motor HI-LO) Position 1 Clutch coil Position 2 Position 3 Position 4 Position encoder ground (Return position) 2H/4H/4L switch signal Speed sensor ground (Return position) Rear speed sensor signal...
Page 435 3D-11 Section Pin No. Name Description Power supply 12, 25 Ground Part time TCCU ground 13, 26 Part time TCCU battery voltage input Ignition switch Ignition switch voltage Input side : ON - above 4V, OFF - below 0.9 V Position 1 Position encoder : recognize shift motor position HIGH - above 4 V, LOW - below 0.9 V...
Page 436 3D-12 TCCU System Position Encoder The position encoder is the code that TCCU can determine the shift motor position. Position Code Motor Position Remark Left stop Zone 1 Zone 2 Input voltage Zone 3 1 : above 4.5 V (HIGH) Zone 4 0 : below 0.5 V Zone 5...
Page 437 3D-13 Shift conditions Shift operation is only allowed when some conditions are satisfied. These shift conditions should be satisfied for 2 seconds before starting motor. The motor has three seconds of delay at its initial operation to do trouble diagnosis. Once the motor starts, the shift conditions are no longer checked.
Page 438 3D-14 POWER FLOW POWER FLOW Switch Transfer 2H, 4H ↔ 4L TCCU Locking Hub Solenoid Vacuum System Operation Locking Hub Operation Transfer Front Propeller Shaft Rear Propeller Shaft Front Axle Rear Axle Front Wheel Rear Wheel PART TIME CHANGED BY EFFECTIVE DATE REXTON SM - 2004.4 AFFECTED VIN...
Page 439 3D-15 2H MODE (REAR WHEEL DRIVE) Rear Axle Transmission (Rear Wheel) Front Axle (Front Wheel) Y220_03D011 Power Flow Transmission Output Shaft Rear Wheel T/C Input Shaft ↓ Rear Propeller Shaft Rear Axle Output Shaft Rear Wheel PART TIME CHANGED BY REXTON SM - 2004.4 EFFECTIVE DATE AFFECTED VIN...
Page 440 3D-16 4H MODE (4WD DRIVE - HIGH SPEED) Rear Axle Transmission (Rear Wheel) Front Axle (Front Wheel) Y220_03D012 Power Flow Transmission TCCU Motor Input Shaft Shift Cam, Rail, Fork Magnetic Output Shaft Clutch Chain Front Propeller Rear Propeller Shaft Shaft PART TIME CHANGED BY EFFECTIVE DATE...
Page 441 3D-17 4L MODE (4WD DRIVE - LOW SPEED) Rear Axle Transmission (Rear Wheel) Front Axle (Front Wheel) Y220_03D013 Power Flow Transmission TCCU Motor Input Shaft Shift Cam, Rail, Fork Planetary Gear (2.483) Chain Output Shaft Front Propeller Rear Propeller Shaft Shaft PART TIME CHANGED BY...
Page 442 3D-18 DIAGNOSTIC INFORMATION AND PROCEDURES GENERAL DIAGNOSIS Symptoms Check Action Electric shift problems • Faulty or damaged TCCU, speed • Overhaul and check, replace if necessary. sensor, motor, clutch or internal wirings • Damaged or worn shift cam, hub, fork •...
Page 443 3D-19 TROUBLE DIAGNOSIS TEST Shift Motor Test • Check short and open for circuit before and during shifting. • When the system detects a fault in shift motor for over 1 second, “4WD CHECK” warning lamp comes on and the trouble code is stored into memory.
Page 444 3D-20 SELF-DIAGNOSIS TEST 1. TCCU detects transfer case system malfunctions and indicates malfunctioning part(s) through flickering of “4WD CHECK” indicator. Using a service connector, connect it to the diagnosis box in the engine room and read the flickering of “4WD CHECK”...
Page 445 3D-21 Trouble Code Reading 1. Position the ignition switch to OFF. 2. Connect the service connector. 3. Position the ignition switch to ON. 4. Read the flickering of “4WD CHECK” indicator and identify the malfunctioning (refer to Diagnosis Table). Y220_03D017 How to Clear the Trouble Code 1.
Page 446 3D-22 DIAGNOSTIC TROUBLE CODE Code Description Action P1806 CAN Bus OFF - Check communication line. - Replace TCCU if necessary. P1805 Defective mode switch - When the mode switch is defective - Check TCCU pin No.4 and 16. - Mode change •...
Page 447 3D-23 Code Description Action P1843 Shift system timeout - 2H-4H: after 1.5 seconds - 4H-4L: after 3 seconds - Check the relevant harnesses for contact. - Replace TCCU if necessary. P1844 Too low position encoder voltage - When no signals from the position encoder (Stuck in Low) - Check the relevant harnesses for contact.
Page 448 3D-24 CIRCUIT DIAGRAM (DI & 5-SPEED A/T) Y220_03D019 PART TIME CHANGED BY EFFECTIVE DATE REXTON SM - 2004.4 AFFECTED VIN...
Page 449 3D-25 MAINTENANCE AND REPAIR OIL LEVEL CHECK AND CHANGE 1. Oil level check • Clean the oil level plug and surroundings. • Remove the oil level plug and check whether oil is spilled out. • Add oil if necessary. • Tighten the oil level plug. Installation Notice Tightening torque 19 ~ 30 Nm...
Page 450 3D-26 REMOVAL AND INSTALLATION OF TRANSFER CASE COMPONENT LOCATOR Rear propeller shaft Transmission Front propeller shaft Y220_03D023 1. Companion flange 6. Input shaft 2. Case cover 7. Front and rear speed sensor 3. Front companion flange 8. Shift motor/electronic magnetic clutch 4.
Page 451 3D-27 Exploded View Y220_03D025 PART TIME CHANGED BY REXTON SM - 2004.4 EFFECTIVE DATE AFFECTED VIN...
Page 452 3D-28 1. Snap ring 36. Name plate 2. Snap ring 37. Output shaft 3. Snap ring 38. Dust shield 4. Bearing 39. Magnet 5. Hub 40. Snap ring 6. Input shaft assembly 41. Lower sprocket 7. Thrust plate 42. Spacer 8.
Page 453 3D-29 REMOVAL AND INSTALLATION Transfer Case Preceding work: Place the selector lever to “N” position. 1. Disconnect the negative battery cable. 2. Lift up the vehicle and fix it safely. 3. Remove the damper mounting bolt. 4. Remove the drain plug and drain the oil. Reinstall the drain plug.
Page 454 3D-30 7. Support the transfer case with jack and remove the front and rear propeller shafts from the transfer case. Installation Notice Front 81 ~ 89 Nm Tightening torque Rear 70 ~ 90 Nm Y220_03D029 8. Remove the center mounting nuts and end sides mounting bolts of the cross member and then remove the cross member.
Page 455 3D-31 TCCU 1. Move the driver’s seat, remove the seat frame cover, and remove the seat frame mounting bolts. Y220_03D032 2. Disconnect the driver’s seat sliding/tilting motor connector and pull back the seat. Y220_03D033 3. Disconnect the TCCU unit connector and remove the TCCU.
Page 456 3D-32 Shift Motor 1. Disconnect the negative battery cable. 2. Disconnect the shift motor/electronic magnetic clutch connector (black, 7-pin) and front and rear speed sensor connector (white, 4-pin) at the rear top section of the transfer case. Y220_03D036 3. Disconnect the front and rear speed sensor connector (white, 4-pin) from bracket.
Page 457 3D-33 7. Clean the mating surface of the transfer case and shift motor. Notice Do not disassemble the shift motor since it is replaced as an assembled unit. Y220_03D040 8. Apply sealant on the mating surface if new shift motor assembly.
Page 458 3D-34 Speed Sensor 1. Disconnect the negative battery cable. 2. Remove the shift motor assembly. 3. Disconnect the front and rear speed sensor connector (white, 4-pin) at the rear top section of the transfer case. 4. Disconnect the speed sensor connector from the locking sleeve.
Page 459 3D-35 10. Hold the “L” pin in speed sensor connector with long nose pliers and push it rearward to disconnect from the connector. 11. Disconnect the “M” and “N” pin and wire from the connector with same manner. Notice EMC wire cannot be disconnected from outside, therefore do not try to disconnect it.
Page 460 3D-36 SPECIAL TOOLS AND EQUIPMENT Name and Part Number Application 661 589 01 37 00 (W 99 31 001 1B) Removal/installation of carrier assembly in transfer case Pliers Y220_03E078 Y220_03E079 SY 220 - 080 (W 99 31 005 0B) Installation of oil seal to transmission case Oil seal installer Y220_03E080...
Page 461 3E-1 SECTION 3E Table of Contents GENERAL INFORMATION AND OPERATION ....3E-3 Overview ..............3E-3 Specifications ............. 3E-5 Cross sectional diagram (TOD transfer case) ..3E-6 TCCU ............... 3E-10 SYSTEM OPERATION ..........3E-13 TCCU system ............3E-13 Electric shift system operation ......... 3E-15 TOD system operation ..........
Page 462 3E-3 GENERAL INFORMATION AND OPERATION OVERVIEW Y220_03E001 Distribution of Driving Force TOD system means the full time 4WD system and the registered trade mark of Borg Warner. TOD is an abbre- According to Road Surface viation of Torque On Demand. 1.
Page 463 3E-4 Function 4L Mode Selection Mode When selecting 4L mode, EMC is locked to apply maximum The TOD system has 2 selectable mode, 4H and 4L. torque into front and rear propeller shafts. Shift motor rotates 4H is the normal operating mode when drive of which also 4L position by rotation of cam thus propeller shaft torque gear ratio is 1:1 and 4L mode distributes power to front changes from 1:1 to 2.48:1 by planetary gear set.
Page 464 4H and 4L Shifting mode Gear ratio High 2.48:1 Oil specification Specification Ssangyong genuine oil (ATF S-3, S-4 or Dexron II/III) Capacity Change interval Check at every 15,000 km, replace at every 60,000 km Maximum torque (front) Approx. 76 kg•m...
Page 465 3E-6 CROSS SECTIONAL DIAGRAM (TOD TRANSFER CASE) Chain Clutch pack 4H-4L planetary gear set Ball lamp Input shaft Oil pump 4H-4L shift motor Front wheel output shaft Y220_03E004 CHANGED BY EFFECTIVE DATE REXTON SM - 2004.4 AFFECTED VIN...
Page 466 3E-7 Shift Motor When selecting a position in 4WD switch (4H/4L), TOD control unit exactly changes the motor position to 4H and 4L by detecting the electric signals from position encoder that monitors motor position. Function Position 4 shift Shift motor LO – HI (clockwise) D (Brown/ E (Purple/White) Position 3...
Page 467 3E-8 Transfer Case Planetary gear set Planetary Gear set consists of sun gear, ring gear and carrier. It is engaged with the gear in “HIGH-LOW” collar to increase the driving force by reducing vehicle speed. Sun gear is connected to input shaft and ring gear is fixed into the transfer case. Splined rear output shaft is able to slide on the “HIGH - LOW”...
Page 468 3E-9 Electro Magnetic Clutch (EMC) EMC consists of coil and housing. TOD control unit controls EMC by controlling duty cycle according to the road and driving conditions. These controls use the continuity time and amount of electric current to determine the torque to be transmitted to front wheels.
Page 469 3E-10 TCCU Y220_03E008 Description New TCCU Connector type Two separated connectors Number of pins Weight 0.22 kg CAN-BUS Vehicle speed signal CAN communication Lamp CAN communication Clutch signal (M/T) CAN communication Neutral signal (A/T) CAN communication Appearance and Function Pin No. Description Pin No.
Page 470 3E-11 Transfer Case Block Diagram Shift motor output Battery voltage (Motor LO-HI) Ignition switch ON/ Shift motor output (Motor HI-LO) Position 1 Position 2 Position 3 Position 4 Position encoder ground (Return position) 4H/4L switch signal Speed sensor ground Front speed (Return position) sensor signal Front/rear speed...
Page 471 3E-12 Section Pin No. Name Description 17, 18 Ground TOD control unit ground Power supply 4, 19 TOD control unit battery voltage input Input side Ignition switch Ignition switch power : ON - over 4 V, OFF - below 0.9 V Position 1 Position encoder –...
Page 472 3E-13 SYSTEM OPERATION TCCU SYSTEM TCCU Initialization • TCCU sends relevant data to meter cluster via CAN to diagnose and check the indicators when the ignition switch is turned to ON. At this time, the 4WD indicators (4WD LOW, 4WD HIGH, 4WD CHECK) comes on for 0.6 seconds. •...
Page 473 3E-14 If 4H/4L switch position is not matched with shift motor position code with the ignition switch “ON”, the shift require- ments operate to the direction of 4H/4L switch. However, the shifting requirements should be met to shift. • Shifting requirements: - The transmission is in neutral for 2 seconds after the shift is requested.
Page 474 3E-15 ELECTRIC SHIFT SYSTEM OPERATION The electric shift system is responsible for changing the transfer case gear ratio by controlling the electric shift motor. The TOD monitors the 4H/4L switch, neutral switch, speed sensors, position encoder, and ignition switch. A range change is initiated when: 1.
Page 475 3E-16 Shift Conditions Shift is allowed only when certain conditions for the vehicle are satisfied. This means that the shift conditions must satisfy the operating conditions for 2 seconds before motor starts and 2 seconds of delay at initial stage is to diagnose the system.
Page 476 3E-17 TOD SYSTEM OPERATION The TOD system is responsible for distributing torque between the front and rear axles. The TOD monitors the propeller shaft speeds, operating range (High/Low), and ABS activity and then applies a calculated amount of torque to the front axle by Pulse Width Modulating the current applied to the EMC.
Page 477 3E-18 SHIFT OPERATION Shifting Sequence Flow chart Start Shift Satisfied shift Check shift conditions for 2 requirements conditions seconds Analyzing position encoder Canceling general encoder Is the position DTC Shift is not available code valid? during ignition cycle Move further to requested direction Does the motor Motor stops Shift...
Page 478 3E-19 Shift Requirements • If 4H/4L switch position is not matched with shift motor position code with the ignition switch “ON”, the shift requirements operate to the direction of 4H/4L conversion switch. • The next shift requirements are identified only when those are different from current operation. Shift Conditions Shift is allowed only when certain conditions for the vehicle are satisfied.
Page 479 3E-20 POWER FLOW System Layout Instrument Panel 4WD Switch Output TOD Control Unit Input Rear Speed Manetic Clutch Motor Front Output Front Speed Y220_03E010 CHANGED BY EFFECTIVE DATE REXTON SM - 2004.4 AFFECTED VIN...
Page 480 3E-21 4H Mode (4WD Drive - High Speed) Rear Axle Transmission (Rear Wheel) Front Axle (Front Wheel) Y220_03E011 Front Speed Sensor Rear Speed Transmission TOD Control Unit Sensor Input Shaft Throttle Open Rate (TPS Value) Magnetic Clutch Output Shaft MAX DUTY Force Distribution Unit BALL RAMP Driving Sprocket...
Page 481 3E-22 4L Mode (4WD Drive - Low Speed) Rear Axle Transmission (Rear Wheel) Front Axle (Front Wheel) Y220_03E012 Front Speed Transmission Sensor Input Shaft Rear Speed TOD Control Unit Sensor Throttle Open Rate (TPS Value) Magnetic Clutch Planetary Gear MAX DUTY (2.483) Force Distribution Unit BALL RAMP...
Page 482 3E-23 TROUBLE DIAGNOSIS TCCU periodically monitors the input and output while the system is in operation. When a fault is detected, the trouble code is stored into TCCU memory. If the ignition switch is turned to “OFF”, TCCU stops monitoring for input and output, however, when the ignition switch is turned to “OFF”...
Page 483 3E-24 Front Sensor Speed Test When the system detects a fault from front speed sensor for over 0.5 second, “4WD CHECK” warning lamp comes on. At this time, the responds from TOD control unit are as follows: • If the system is in “4H” state, the TOD control unit uses rear speed sensor value to determine the amount of EMC touch off and the wheel slip control stops.
Page 484 3E-25 CAN TPS Test • When TCCU receives CAN message including TPS value of over 100 % continuously for 1 second, TCCU determines it as signal error and “4WD CHECK” warning lamp comes on. When the system is in TOD mode, the TOD control unit considers that the throttle is in idle. •...
Page 485 3E-26 CODING ON TOD CONTROL UNIT What’s Coding? An input activity of data for the proper performance by match- ing specification, devices and system with control unit. Coding required 1. Replacement of TOD control unit. 2. Adjustment by input error. Coding method 1.
Page 486 3E-27 DIAGNOSTIC TROUBLE CODE Code Description Action P1806 CAN Bus OFF - Check communication line. - Check the relevant connectors for contact. - Replace TOD unit if necessary. P1816 CAN: abnormal TPS signal - Check communication line. - Check the relevant connectors for contact. - Check engine ECU.
Page 487 3E-28 Code Description Action P1835 Too low speed sensor reference voltage - Reference voltage: below 4 V - Check the relevant harnesses. - Check the relevant connectors for contact. - Replace sensors if necessary. P1836 Too high speed sensor reference voltage - Reference voltage: over 8V - Check the relevant harnesses.
Page 488 3E-29 Circuit Diagram Y220_03E014 CHANGED BY REXTON SM - 2004.4 EFFECTIVE DATE AFFECTED VIN...
Page 489 3E-30 REMOVAL AND INSTALLATION COMPONENT LOCATOR Rear propeller shaft Transmission Front propeller shaft Y220_03E015 1. Companion flange 6. Input shaft 2. Case cover 7. Front and rear speed sensor 3. Front companion flange 8. Shift motor/electronic magnetic clutch 4. Air adjusting cover 9.
Page 490 3E-31 EXPLODED VIEW Y220_03E017 CHANGED BY REXTON SM - 2004.4 EFFECTIVE DATE AFFECTED VIN...
Page 491 3E-32 1. Snap ring 35. Breather 2. Snap ring 37. Output shaft 3. Snap ring 38. Dust shield 4. Bearing 39. Magnet 5. Hub 40. Snap ring 6. Input shaft assembly 41. Lower sprocket 7. Thrust plate 42. Tone wheel (lower) 8.
Page 492 3E-33 Removal and Installation 1. Disconnect the negative battery cable. 2. Lift up the vehicle and fix it safely. 3. Place the empty container to collect the draining oil. 4. Remove the drain plug and drain the oil. Reinstall the drain plug.
Page 493 3E-34 9. Remove the rear propeller shaft mounting bolts (4). Y220_03E021 10. Unscrew the bolts and remove the crossmember from the transmission. L/R Mounting Bolt 21 ~ 35 Nm Center Mounting Bolt 62 ~ 93 Nm Y220_03E022 11. Remove the insulator mounting bolts. Installation Notice Tightening torque 62 ~ 93 Nm...
Page 494 3E-35 TCCU Removal and Installation 1. Move the driver’s seat, remove the seat frame cover, and remove the seat frame mounting bolts. Y220_03E039 2. Disconnect the driver’s seat sliding/tilting motor connector and pull back the seat. Y220_03E040 3. Disconnect the TCCU unit connector and remove the TCCU.
Page 495 3E-36 SHIFT MOTOR Removal and Installation 1. Disconnect the negative battery cable. 2. Disconnect the shift motor/electronic magnetic clutch connector (black, 7-pin) and front and rear speed sensor connector (white, 4-pin) at the rear top section of the transfer case. Y220_03E025 3.
Page 496 3E-37 6. Pull the shift motor assembly out while keeping the level. Y220_03E028 7. Clean the mating surface of the transfer case and shift motor. Notice Do not disassemble the shift motor since it is replaced as an assembled unit. Y220_03E029 8.
Page 497 3E-38 SPEED SENSOR Removal and Installation 1. Disconnect the negative battery cable. 2. Remove the shift motor assembly. 3. Disconnect the front and rear speed sensor connector (white, 7-pin) at the rear top section of the transfer case. 4. Disconnect the speed sensor connector from the locking sleeve.
Page 498 3E-39 8. Remove the tapings in both sides of protective tube. 9. Remove the tube. Y220_03E033 10. Hold the “L” pin in speed sensor connector with long nose pliers and push it rearward to disconnect from the connector. 11. Disconnect the “M” and “N” pin and wire from the connector with same manner.
Page 499 3E-40 SPECIAL TOOLS AND EQUIPMENT Name and Part Number Application 661 589 01 37 00 (W 99 31 001 1B) Removal/installation of carrier assembly in transfer case Pliers Y220_03E078 Y220_03E079 SY 220 - 080 (W 99 31 005 0B) Installation of oil seal to transmission case Oil seal installer Y220_03E080...
Page 500 SECTION AXLE & PROPELLER SHAFT CONTENTS FRONT AXLE..............4A REAR AXLE ..............4B PROPELLER SHAFT ............ 4C...
Page 501 4A-1 SECTION 4A FRONT AXLE Table of Contents GENERAL INFORMATION ..........4A-3 Specification ............... 4A-3 Component locator ............ 4A-4 REMOVAL AND INSTALLATION ........4A-6 Front axle shaft (for part time T/C) ......4A-6 Axle housing assembly ..........4A-13 Vacuum line .............. 4A-15 DISASSEMBLY AND REASSEMBLY ......
Page 502 4A-3 GENERAL INFORMATION SPECIFICATION Description Specification Drive shaft type CV (constant velocity) joint Axle housing type Build-up Differential Type Conventional Gear type Hypoid Final gear reduction DI engine + M/T 3.73 ratio 3.31 DI engine + A/T Gasoline engine + A/T 4.27 1.4 liter (DI engine + Tongil axle: 1.5 liter) Capacity...
Page 503 4A-4 COMPONENT LOCATOR Front Axle Housing Y220_04A001 1. Axle tube assembly 7. Inner shaft (LH) 2. Snap ring 8. Inner shaft (RH) 3. Ball bearing 9. Bolt 4. Oil seal 10. Front axle bracket (LH) 5. Protector 11. Front axle bracket (RH) 6.
Page 504 4A-5 Axle Shaft (Drive Shaft) Y220_04A002 1. Drive shaft 7. Boot band 2. Housing (inboard) 8. Boot band 3. Boot (outboard) 9. Boot band 4. Boot (inboard) 10. Seal 5. Shaft 11. Ball joint 6. Boot band FRONT AXLE CHANGED BY REXTON SM - 2004.4 EFFECTIVE DATE AFFECTED VIN...
Page 505 4A-6 REMOVAL AND INSTALLATION FRONT AXLE SHAFT (FOR PART TIME T/C) Removal 1. Remove the tire. Y220_04A004 2. Vehicle with ABS system (Only for part time T/C equipped vehicle) Unscrew the mounting bolt and remove the wheel speed sensor and cable from steering knuckle. Y220_04A005 3.
Page 506 4A-7 4. Unscrew two bolts (arrows) and remove the brake caliper assembly. Notice Be careful not to damage the brake oil hose. Y220_04A007 5. Vehicle with part time transfer case only. 1) Remove the hub mounting bolt and washer, and remove the hub cover.
Page 507 4A-8 4) Remove the hub and brake disc assembly. Y220_04A011 6. Vehicle with full time transfer case only 1) Remove the hub nut and washer. 2) Remove the front disc assembly from axle shaft. Installation Notice Replace the nut with new one, and caulk the nut end to lock the nut.
Page 508 4A-9 8. Remove the split pin and nut from the connection of the upper arm and steering knuckle. Installation Notice Replace the wheel split pin with new one. 9. Remove the split pin and nut from the connection of the lower arm and steering knuckle.
Page 509 4A-10 Installation Clean all the removed elements. Check O-ring and snap ring for wear and damage. Replace the defective elements with new ones. 1. Install the axle shaft to axle housing. Make sure to securely seat the axle shaft onto the housing. Notice Be careful not to damage the boots during installation.
Page 510 4A-11 2) Install the washer and hub nut. Caulk the nut end to lock the nut. After caulking, apply grease or paint on the caulked area. Tightening torque 250 ~ 350 Nm 3) Install the brake disc and brake caliper. Y220_04A020 6.
Page 511 4A-12 7. Tighten the front disc brake caliper mounting bolts with the front disc installed. Tightening torque 85 ~ 105 Nm Y220_04A024 8. Install the steering linkage end to steering knuckle and tighten the slotted nut Notice Replace the split pin with new one. Tightening torque 35 ~ 45 Nm 9.
Page 512 4A-13 AXLE HOUSING ASSEMBLY Preceding work: Removal of axle shaft Y220_04A026 1. Axle mounting bracket 9. Nut 2. Breather hose 10. Front axle housing 3. Bolt 11. Nut 4. Nut 12. Bolt 5. Bolt 13. Washer 6. Bush 14. Washer - spring 7.
Page 513 4A-14 Removal and Installation Preceding work: Removal of axle shaft 1. Remove the propeller shaft from the front axle input shaft. Installation Notice Tightening torque 70 ~ 80 Nm 2. Remove the steering gear linkage. Y220_04A027 3. Remove the breather hose. Y220_04A027A 4.
Page 514 4A-15 VACUUM LINE To knuckle-RH To Vacuum Pump To knuckle-LH Y220_04A031 1. Vacuum type auto locking hub hssembly 10. Molded hose 2. Bolt ............30 ~ 40 Nm 11. Check valve 3. Washer 12. Corrugated tube 4. Auto locking hub cap 13.
Page 515 4A-16 Removal and Installation Notice 1. Be careful not to change the direction of valves when connecting the check valve (11) to hoses. Y220_04A032 2. Adjust the clearance between the retainer ring (5) and locking hub (7) to the specified value by using the appropriate shims (6).
Page 516 4A-17 DISASSEMBLY AND REASSEMBLY EXPLODED VIEW Front Axle Housing Y220_04A034 FRONT AXLE CHANGED BY REXTON SM - 2004.4 EFFECTIVE DATE AFFECTED VIN...
Page 517 4A-18 1. Front axle housing mounting bracket 21. Oil slinger 2. Inner shaft (left) 22. Driver pinion 3. Bolt 23. Oil filler plug 4. Oil seal ..replace, apply grease to the sealing rib 24. Bolt 5. Snap ring 25. Axle housing cover ..... apply liquid gasket 6.
Page 518 4A-19 AXLE HOUSING ASSEMBLY Disassembly 1. Remove the drain plug and drain the oil. Install the drain plug. Installation Notice Tightening torque 28 ~ 42 Nm Y220_04A035 2. Unscrew the axle housing mounting bracket bolts and remove the bracket and inner shaft assembly. Y220_04A036 3.
Page 519 4A-20 4. Remove the axle housing cover. Notice Remove the gasket residues from cover and housing mating surface. Y220_04A038 5. Unscrew bolts and remove the bearing cap, then remove the differential carrier assembly. Notice Before removal, place the alignment marks on the bearing cap so that they cannot be changed.
Page 520 4A-21 Inspection of Ring Gear Tooth Contact Pattern 1. Normal Contact Apply gear-marking compound (Prussian blue / red lead) on the ring gear teeth. Rotate the ring gear and check the tooth contact pattern. Y220_04A042 2. Abnormal Contact Tooth Contact pattern Possible Cause Remedy 1.
Page 521 4A-22 Assembly 1. Clean all parts and check the followings: • Check the ring gear, drive pinion for wear and damage. If damaged, replace it as a set. • Check the bearing for sticks, wear, noise and turning resistance. • Check the side gear, pinion, pinion shaft and thrust washer for wear and damage.
Page 522 4A-23 6. Measure the backlash between drive pinion and ring gear. Specified value 0.13 ~ 0.20 mm Y220_04A055 7. Install the axle housing cover. Tightening torque 39 ~ 46 Nm Y220_04A056 8. Assemble the front axle inner shaft and housing mounting bracket components.
Page 523 4A-24 DIFFERENTIAL JOINT ASSEMBLY Disassembly 1. Remove the drive axle. 2. Remove the joint boot clamp. (1) Remove the larger boot clamp. • Compress the clamp tabs with special tool. (2) Remove the smaller boot clamp. • Unfold the clamp holding with a screwdriver. Y220_04A059 3.
Page 524 4A-25 Inspection 1. Check the shaft spline for wear and damage. 2. Check the boot for crack and leaks by tearing. 3. Check the shaft for bend. Notice If any of shafts is defective, both shafts should be replaced as a set since the other shaft is liable to be affected.
Page 525 4A-26 WHEEL JOINT Disassembly 1. Remove the drive axle. 2. Remove the joint boot clamp. (1) Remove the larger boot clamp. (2) Remove the smaller boot clamp. • Unfold the clamp holding with a screwdriver. Y220_04A065 3. Remove the grease on the joint assembly. 4.
Page 526 4A-27 Assembly 1. Assemble in the reverse order of disassembly. 2. Install the joint assembly. • Insert the joint assembly into the drive axle shaft until the circlip opens slightly. (1) Keep the openings with screwdriver. (2) Insert the joint assembly until it reaches to the circlip groove.
Page 527 4A-28 TROUBLE DIAGNOSIS Symptom Cause Action Noise (during straight Lack of oil Replenish driving) Low viscosity of oil Replace Inferior oil Replace Excessive backlash of ring gears Adjust Worn or damaged tooth of ring and pinion gear Replace Worn or damaged tooth of drive pinion gear Replace Wear of side bearing and side gear spline Replace...
Page 528 4A-29 SPECIAL TOOLS AND EQUIPMENT Name and Part Number Application 661 589 13 33 00 Ball joint remover Y220_04A071 Y220_04A072 SY 340 - 080 (L 99 42 014 0B) Supporting the front axle Front drive axle stand during removal and installation Y220_04A073 Y220_04A074 SY 340 - 090 - 01 (W 99 42 001 1B)
Page 529 4A-30 Name and Part Number Application SY 340 - 060 (W 99 48 010 0A) Removal and installation of front hub cap Front hub cap remover and in- Using with SY340-050 (sliding staller hammer) Y220_04A079 Y220_04A080 SY 340 - 070 (W 99 48 011 0A) Removal and installation of front hub flange Front hub flange remover...
Page 530 4B-1 SECTION 4B REAR AXLE Table of Contents GENERAL INFORMATION ..........4B-3 Specifications ............. 4B-3 Components locator ..........4B-4 Cross sectional view ..........4B-5 REMOVAL AND INSTALLATION ........4B-6 Rear axle shaft ............4B-6 Rear axle housing ............ 4B-13 DISASSEMBLY AND REASSEMBLY ......4B-18 Exploded view ............
Page 531 4B-3 GENERAL INFORMATION SPECIFICATIONS Description Specification Axle shaft type Semi-floating Axle housing type Build up Differential Type Conventional type Gear type Hypoid Gear Final gear reduction ratio DI engine + M/T 3.73 DI engine + A/T 3.31 Gasoline engine + A/T 4.27 Capacity Specification...
Page 532 4B-4 COMPONENTS LOCATOR Y220_04B001 1. Axle shaft/Tube 5. Shock absorber 2. Stabilizer bar 6. Lateral rod 3. Spring seat and spring 7. Flange 4. Upper arm 8. Axle housing REAR AXLE CHANGED BY EFFECTIVE DATE REXTON SM - 2004.4 AFFECTED VIN...
Page 533 4B-5 CROSS SECTIONAL VIEW Y220_04B002 1. Rear axle shaft assembly 6. Coil spring seat (lower) 2. Brake assembly (parking brake) 7. Carrier assembly 3. Oil seal - inner 8. Input shaft/Flange 4. Bolt 9. Rod mounting bracket 5. Axle shaft tube 10.
Page 534 4B-6 REMOVAL AND INSTALLATION REAR AXLE SHAFT Disc Brake Equipped Vehicle Y220_04B003 1. Brake disc 7. Parking brake lining and back plate assembly 2. Plug 8. Brake caliper assembly 3. Rear axle shaft 9. Spring washer 4. Nut 10. Bolt 5.
Page 535 4B-7 Removal 1. Remove the tire. Y220_04B004 2. Release the parking brake. 3. Remove the parking brake lock pin. 4. Remove the parking brake lever and disconnect the cable. Y220_04B005 5. Remove two brake caliper bolts (1). Notice Be careful not to damage the brake oil hose. 6.
Page 536 4B-8 8. Remove two plastic plugs from the axle shaft flange. Y220_04B009 9. Unscrew four bolts and remove the dust shield cover. 10. Remove four axle housing flange bolts and washers with retainer plate. 11. Remove the rear axle drive shaft. Y220_04B008 REAR AXLE CHANGED BY...
Page 537 4B-9 Installation Clean the disassembled axle shaft and check it damage or wear. 1. Check the rear axle shaft spline and insert it into the rear axle housing. 2. Install four axle housing flange bolts and washers with retainer plate. Tightening torque 50 ~ 65 Nm 3.
Page 538 4B-10 Drum Brake Equipped Vehicle Y220_04B012 1. Brake drum 9. Bearing 2. Plug 10. Retainer ring 3. Rear axle shaft 11. Snap ring 4. Wheel bolt 12. Oil seal 5. Nut 13. Brake shoe and back plate assembly 6. Washer 14.
Page 539 4B-11 Removal 1. Release the parking brake. 2. Remove the tire. Y220_04B013 3. Remove the brake drum. Notice Insert two bolts into the service holes and tighten both bolts evenly. 4. Remove the parking brake lock pin. 5. Remove the parking brake cover and disconnect the parking brake cable.
Page 540 4B-12 7. Remove the axle shaft. Y220_04B017 Installation 1. Check the rear axle shaft. 2. Insert the rear axle shaft into the axle housing and tighten the flange nuts. Tightening torque 50 ~ 65 Nm Y220_04B018 3. Connect the parking brake cable and install the brake drum.
Page 541 4B-13 REAR AXLE HOUSING Removal 1. Remove the tire. 3. Remove the air breather (5). 2. Remove the brake oil hoses and pipes. 4. Remove the propeller shaft from rear axle input shaft. (1) Brake pipe flare nut (2) Brake pipe mounting clip Notice (3) 3-way connector Place an alignment mark before removing.
Page 542 4B-14 5. Remove the parking brake lock pin. 6. Remove the parking brake lever and disconnect the cable. Y220_04B024 7. Unscrew the nuts and remove the lower arm from axle housing. Y220_04B025 8. Separate the shock absorber base from axle housing. Y220_04B026 9.
Page 543 4B-15 10. Remove the stabilizer bar. Y220_04B028 11. Unscrew the nuts and remove the lateral rod from axle housing. Y220_04B029 12. Remove the coil spring and spring seat while lowering one end of axle very carefully. 13. Lower the safety axle very carefully to remove the axle. Y220_04B030 Installation 1.
Page 544 4B-16 2. Install the lateral rod to axle housing. Notice Do not fully tighten the nut. Tightening torque 2 150 ~ 180 Nm 3. Install the shock absorber base to axle housing. Tightening torque 3 50 ~ 65 Nm Y220_04B032 4.
Page 545 4B-17 Inspection 1. Check the shaft spline for wear and damage. Y220_04B036 2. Measure the run-out of shaft. Specified value below 1.0 mm Y220_04B037 3. Measure the run-out at bearing hub in shaft flange. Specified value below 0.13 mm Y220_04B038 4.
Page 546 4B-18 DISASSEMBLY AND REASSEMBLY EXPLODED VIEW Y220_04B040 REAR AXLE CHANGED BY EFFECTIVE DATE REXTON SM - 2004.4 AFFECTED VIN...
Page 547 4B-19 1. Drive pinion lock nut ......240 ~ 310 nm 17. Bolt ............87 ~ 124 Nm 2. Washer 18. Bearing 3. Companion flange 19. Shim 4. Pinion oil seal 20. Ring gear 5. Bearing slinger 21. Shaft lock pin 6.
Page 548 4B-20 REAR AXLE ASSEMBLY Disassembly 1. Remove the drain plug and drain the oil. Install the drain plug. Tightening torque 28 ~ 42 Nm Drain Plug Y220_04B041 2. Remove the axle housing cover. Notice Remove the gasket residues from cover and housing mating surface.
Page 549 4B-21 4. Disassemble the differential carrier assembly. Y220_04B044 5. Unscrew the lock nut and disassemble the driving pinion assembly. Y220_04B045 REAR AXLE CHANGED BY REXTON SM - 2004.4 EFFECTIVE DATE AFFECTED VIN...
Page 550 4B-22 Inspection of Ring Gear Tooth Contact Pattern 1. Normal Contact Apply gear-marking compound (Prussian blue / red lead) on the ring gear teeth. Rotate the ring gear and check the tooth contact pattern. Y220_04B046 2. Abnormal Contact Tooth Contact Pattern Possible Cause Remedy 1.
Page 551 4B-23 Assembly 1. Clean all parts and check the followings: • Check the ring gear, drive pinion for wear and damage. If damaged, replace it as a set. • Check the bearing for sticks, wear, noise and turning resistance. • Check the side gear, pinion, pinion shaft and thrust washer for wear and damage.
Page 552 4B-24 5. Install the differential carrier assembly into the axle housing. Install the bearing cap. Tightening torque 240 ~ 310 Nm Notice Be careful not to mix the caps. Y220_04B059 6. Measure the backlash between drive pinion and ring gear. Specified value 0.13 ~ 0.20 mm Y220_04B060...
Page 553 4B-25 TROUBLE DIAGNOSIS Symptom Cause Action Noise (during straight Lack of oil Replenish driving) Low viscosity of oil Replace Inferior oil Replace Excessive backlash of ring gears Adjust Worn or damaged tooth of ring and pinion gear Replace Worn or damaged tooth of drive pinion gear Replace Wear of side bearing and side gear spline Replace...
Page 554 4B-26 SPECIAL TOOLS AND EQUIPMENT Name and Part Number Application SY 340 - 090 - 01 (W 99 42 001 1B) Removal and installation of drive axle differential gear Drive differential remover and installer Y220_04B062 Y220_04B063 SY 340 - 090 - 03 (W 99 42 003 1B) Removal and installation of rear drive axle differential gear Rear drive differential remover...
Page 555 4C-1 SECTION 4C PROPELLER SHAFT Table of Contents GENERAL INFORMATION ..........4C-3 Overview ..............4C-3 Specification ............... 4C-3 Component locator ............ 4C-4 Propeller shaft assemble ........... 4C-5 REMOVAL AND INSTALLATION ........4C-6 DISASSEMBLY AND REASSEMBLY ......4C-11 TROUBLE DIAGNOSIS ..........4C-14 SPECIAL TOOLS AND EQUIPMENT ......
Page 556 4C-3 GENERAL INFORMATION OVERVIEW The propeller shaft transfers the power through the transmis- sion and transfer case to the front/rear axle differential carrier (final reduction gear). It is manufactured by a thin rounded steel pipe to have the strong resisting force against the torsion and bending.
Page 557 4C-4 COMPONENT LOCATOR Cross Sectional View Front Propeller Shaft Axle Rear Propeller Shaft Axle Y220_04C002 1. Flange yoke 8. Split washer 2. Journal bearing cap 9. Slip tube shaft 3. Spider journal 10. Tube 4. Slip yoke assembly 11. Tube yoke 5.
Page 558 4C-5 PROPELLER SHAFT ASSEMBLE Y220_04C003 1. Bolt 5. Bolt 2. Front propeller shaft 6. Rear propeller shaft 3. Bolt 7. Bolt 4. Transfer case PROPELLER SHAFT CHANGED BY REXTON SM - 2004.4 EFFECTIVE DATE AFFECTED VIN...
Page 559 4C-6 REMOVAL AND INSTALLATION Part Time T/C Removal 1. Place the alignment on the propeller shaft. Y220_04C004 Y220_04C031 PROPELLER SHAFT CHANGED BY EFFECTIVE DATE REXTON SM - 2004.4 AFFECTED VIN...
Page 560 4C-7 2. Remove the front propeller shaft. Part Time T/C Y220_04C005 Y220_04C032 3. Remove the transfer case flange yoke bolts and nuts from rear propeller shaft. Y220_04C006 4. Remove the intermediate bearing (center) bolts. Y220_04C007 PROPELLER SHAFT CHANGED BY REXTON SM - 2004.4 EFFECTIVE DATE AFFECTED VIN...
Page 561 4C-8 5. Unscrew the rear axle housing flange yoke bolts and nuts and remove the rear propeller shaft assembly. Y220_04C008 Y220_04C033 PROPELLER SHAFT CHANGED BY EFFECTIVE DATE REXTON SM - 2004.4 AFFECTED VIN...
Page 562 4C-9 Installation 1. Check the removed elements. 2. Align the marks on each propeller shaft. 3. Install the front propeller shaft. Axle 70 ~ 80 Nm Transfer case 80 ~ 88 Nm Y220_04C009 4. Place the rear propeller shaft between transmission and axle housing and temporarily install the intermediate (center) bearing.
Page 563 4C-10 DISASSEMBLY AND REASSEMBLY Disassembly 1. Place an alignment mark and remove the propeller shaft. 2. Place an alignment on the spiders before removing. Y220_04C012 3. Remove the snap ring with snap ring pliers. Y220_04C013 4. Tap the yoke shoulder on shaft with copper hammer to remove the roller bearing.
Page 564 4C-11 5. If it cannot be removed, hold the welding area with vise and remove the needle bearing by using a suitable drift and hammer. Y220_04C015 6. Disassemble the universal joint. The universal joint compensates the angle changes due to vertical movement of the axle shaft. Y220_04C016 7.
Page 565 4C-12 Check 1. Visual Check Check the components for wear and crack and replace if needed. 2. Outer diameter of spider journal Specified value 17.893 mm Limit 17.910 mm Y220_04C018 3. Clearance between spider journal and bearing Specified value 0.03 ~ 0.098 mm Limit 0.25 mm Y220_04C019...
Page 566 4C-13 Assembly Flange yoke Clean the components and replace if damaged. 1. Align the alignment marks on the yoke and assemble the spider, bearing and snap ring. Spider Bearing Snap ring Yoke Y220_04C022 2. Apply the grease to the inner lip of needle roller bearing and assemble the needle roller.
Page 567 4C-14 TROUBLE DIAGNOSIS Symptom Cause Action Vibration Poor installation of sliding joint Adjust Bending of propeller shaft replace Incorrect symmetry of universal joint snap rings Adjust Loose yoke bolt Tighten Noise Worn or damaged universal joint bearing Replace Missing universal joint snap ring Adjust and replace Loose yoke connection Tighten...
Page 568 4C-15 SPECIAL TOOLS AND EQUIPMENT Name and Part Number Application 116 589 09 43 00 (P 99 48 003 0A) Centering the clutch disc Remover and installer Y220_04C027 Y220_04C028 129 589 00 34 00 (P 99 33 002 0B) Removal of bearing Pulling arms Y220_04C029 Y220_04C030...
Page 569 MEMO ..................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................
Page 570 SECTION WHEEL & SHAFT...
Page 571 5A-1 SECTION 5A WHEEL & TIRE Table of Contents DESCRIPTION AND OPERATION ........5A-3 General ..............5A-3 Specifications ............. 5A-5 Tire’s abnormal action ..........5A-6 Wheel alignment ............5A-7 REMOVAL AND INSTALLATION ........5A-9 MAINTENANCE AND REPLACEMENT ......5A-11 Separation ............... 5A-11 Maintenance ............
Page 572 5A-3 DESCRIPTION AND OPERATION GENERAL Tire and Wheel Balancing There are two types of the tire and wheel balancing: static 2. Breaker and dynamic. A cord belt between tread and carcass prevents Static balance is the equal distribution of weight around damages of inner code due to outer shock and the wheel.
Page 573 5A-4 Conventions for Radial Tire The Relations Between Inflation Pressure and Tire P 235 102 T Max Speed : 190 km/h Excessive Air-Pressure Life Load Index : ( % ) 850 kg Insufficient Air-Pressure Rim Diameter : 16 inch. Radial Tire Air-Pressure to Standard air-Pressure (%) Aspect Ratio = (Section Height ÷...
Page 574 5A-5 SPECIFICATIONS Description Specification Wheel Size Aluminum type 7JJ x 16 8 ~ 12 kgf . m Wheel nut tightening Aluminum wheel torque Tire Type Radial tire Radial Tire Inflation pressure (psi) P235/70R16 30 psi P255/65R16 30 psi Wheel alignment Toe-in 2 ±...
Page 575 5A-6 TIRE’S ABNORMAL ACTION Standing Wave Hydroplaning High speed Low speed driving driving Y220_05A005 Y220_05A006 During running the rotating tire repeats deformation and The condition of driving a vehicle fast on the road surface restoring movement generated in tread. But when the wheel covered with water can cause tires to fail to rotate with a rotating speed reaches high, the next deformation applied good contact on the surface, so results in remaining them...
Page 576 5A-7 WHEEL ALIGNMENT The first responsibility of engineering is to design safe Camber steering and suspension systems. Each component must be strong enough to with stand and absorb extreme punish- ment. Both the steering system and the front and the rear suspension must function geometrically with the body Tire center- Perpendicular-...
Page 577 5A-8 Caster Front side Center line Center line Steering Steering axle axle Caster (+) Caster 0 Caster (-) Y220_05A009 Caster is the tilting of the uppermost point of the steering axis either forward or backward from the vertical when viewed from the side of the vehicle. A backward tilt is posi- tive and a forward tilt negative.
Page 578 5A-9 REMOVAL AND INSTALLATION Tire 1. Remove the wheel cap. Y220_05A011 2. Support the vehicle with safety jack. Loosen the wheel nuts and raise the vehicle carefully. 3. Remove the wheel nuts. Y220_05A012 4. Install in the reverse order of removal. Notice •...
Page 579 5A-10 Spare Tire 1. Prepare the spare tire handle and wheel nut wrench. 2. Install the handle through the hole at the rear side of the vehicle. 3. Connect the wheel nut wrench at the end of the handle. 4. Turn the wheel nut wrench counterclockwise until the wire is loosened.
Page 580 5A-11 MAINTENANCE AND REPLACEMENT SEPARATION 1. Fix the tire into the equipment and pull out the valve core from the tire. Discharge the air inside the tire completely. Notice The assembly and disassembly of the tire is dangerous working job. So, only the skillful worker must work this job following the approved procedures.
Page 581 5A-12 5. Apply the lubricant between the rim and the bead. Y220_05A019 6. Insert the removal lever between the tire’s bead and the rim and separate the rim from the tire. Notice Do not use the tool that may cause any damage such as pipe, damaged bar.
Page 582 5A-13 INSTALLATION 1. Clean the rust, damaged rubber and dust, etc on the rim’s surface with the brush. Y220_05A022 2. Install the rim to the equipment with the valve upward. 3. Tighten the locker in the center of the equipment to assemble the rim to the equipment.
Page 583 5A-14 6. Set the tire pressure to the specifications. Notice Do not remove the tire from the equipment before setting the tire pressure. Specification of the ⋅ 30 psi (2.1 kg tire pressure Y220_05A026 WHEELS & TIRE CHANGED BY EFFECTIVE DATE REXTON SM - 2004.4 AFFECTED VIN...
Page 584 5A-15 INSPECTION VISUAL CHECK Condition Cause Action Rapid wear at Under inflation or lack of rotation Adjust inflation pressure shoulders Y220_05A028 Y220_05A029 Rapid wear at center Over inflation or rotation Y220_05A030 Y220_05A031 Tread damage Low the inflation pressure Y220_05A032 Y220_05A033 Uneven wear Incorrect camber Adjust camber...
Page 585 5A-16 Condition Cause Action Feathered edge Incorrect toe-in Adjust toe-in Y220_05A036 Y220_05A037 Bold spot Unbalanced wheel Adjust wheel balance Y220_05A038 Y220_05A039 Sharply wear at the tread outside Unbalanced wheel Adjust Wheel bearing play Check play Check pre-load Ball joint play Check Faulty shock absorber Check...
Page 586 5A-17 GENERAL INSPECTION Tread Inspect the tread condition on the tire surface and various damages resulting from the foreign material, crack, stone or nail etc. If there is any damage in the tire, repair or replace it. Tire Wear • Measure the depth of the tire tread. If the depth of the tread is below the specified value, replace the tire.
Page 587 5A-18 Wheel Runout Measure wheel runout with an accurate dial indicator. Mea- surement may be taken with the wheels either on or off the vehicle, using an accurate mounting surface such as a wheel balancer. Measurements may be taken with or without the tire mounted on the wheel.
Page 588 5A-19 ROTATION OF TIRES Front and rear tires perform different jobs and can wear differ- ently depending on the tires of road driven, driving condition, etc. The front tires will wear faster than the rear ones. To avoid uneven wear of tires and to prolong tire life, inspect and rotate the tires every 5,000 km (3,100 miles).
Page 589 5A-20 TROUBLE DIAGNOSIS Condition Cause Action Irregular tires wear Improper tire inflation pressure Adjust Poor wheel balance Adjust Improper tire rotation Rotation tires on the maintenance schedule Poor toe-in Adjust Poor adjusting the pre-load of the wheel bearing Adjust Poor braking performance Adjust Driving noise, vibration Low tire inflation pressure...
Page 590 SECTION STEERING SYSTEM CONTENTS STEERING COLUMN ............ 6A ECPS ................6B POWER STEERING ............6C...
Page 591 6A-1 SECTION 6A STEERING COLUMN Table of Contents GENERAL INFORMATION ..........6A-3 Overview ..............6A-3 System layout ............. 6A-4 Tightening torque ............6A-5 REMOVAL AND INSTALLATION ........6A-6 Components locator ..........6A-6 DISASSEMBLY AND REASSEMBLY ......6A-14 TROUBLE DIAGNOSIS ..........6A-15 SPECIAL TOOLS AND EQUIPMENT ......
Page 592 6A-3 GENERAL INFORMATION OVERVIEW Column and Shaft Assembly When colliding the steering wheel and column release the impact by the steering wheel and also are designed in order that the steering column shaft may be folded or ab- sorb the impact. The steering column has the ignition switch and lock cylinder.
Page 593 6A-4 SYSTEM LAYOUT Steering Column Assembly Y220_06A004 1. Steering wheel 4. Steering gear assembly 2. Column shaft assembly 5. ECPS solenoid valve 3. Lower shaft assembly STEERING COLUMN CHANGED BY EFFECTIVE DATE REXTON SM - 2004.4 AFFECTED VIN...
Page 594 6A-5 TIGHTENING TORQUE Description Kgf m Steering column Steering column mounting bolt (upper) 2.0 ~ 2.5 20 ~ 25 shaft Steering column mounting bolt (lower) 1.8 ~ 2.5 18 ~ 25 Steering wheel and steering column shaft lock nut 4.0 ~ 6.0 40 ~ 60 Steering column and airbag module connection bolt 0.7 ~ 1.1...
Page 595 6A-6 REMOVAL AND INSTALLATION COMPONENTS LOCATOR Y220_06A007 1. Steering column shaft 5. Bolt 2. Lower shaft 6. Washer 3. Bolt 7. Bolt 4. Nut STEERING COLUMN CHANGED BY EFFECTIVE DATE REXTON SM - 2004.4 AFFECTED VIN...
Page 596 6A-7 Steering Column - Removal 1. Disconnect the negative battery cable and place the tires to straight ahead direction. 2. Unscrew the screws at both sides of steering wheel and remove the horn pad (air bag module). Disconnect the air bag module connector. Y220_06A008 3.
Page 597 6A-8 6. Unscrew the instrument panel side bolts and screws and remove the panel. Y220_06A012 7. Unscrew the bolts and remove the steering column upper cover and lower cover. Y220_06A013 8. Disconnect the multifunction switch connector and fuel- cut vacuum hose. Y220_06A014 9.
Page 598 6A-9 10. Remove the multifunction switch assembly. Y220_06A016 11. Place an alignment mark on the steering column shaft and lower shaft and remove the column shaft upper mounting bolts. Y220_06A017 12. Loosen the steering column shaft housing bolts. Y220_06A018 13. Unscrew the upper mounting bolts (2) and remove the steering column assembly.
Page 599 6A-10 Steering Column - Installation 1. Insert the steering column lower shaft into the gear box (spline) and tighten the bolts. Notice • Install the lower shaft so that the bolt can be inserted into the area without spline. • Install it with aligning the marks. Tightening torque 25 ~ 30 Nm Y220_06A020...
Page 600 6A-11 6. Install the multifunction switch assembly to the steering column shaft. Y220_06A024 7. Install the contact coil to the steering column shaft. Notice When adjusting the neutral position of contact coil, rotate the contact coil to clockwise direction until it stops and then again rotate it by 2.9 ±...
Page 601 6A-12 10. Install the fuse box, cables and switches and install the panel side cover. Notice Insert the side cover into the molding as shown in the figure. Y220_06A028 11. Install the steering wheel with aligning the marks on the steering column shaft and steering wheel nut.
Page 602 6A-13 Steering Lower Shaft - Removal and Installation 1. Unscrew the upper bolts on the steering lower shaft. Y220_06A031 2. Unscrew the lower shaft bolts to steering gear box and remove the steering lower shaft. Notice Place an alignment mark. Y220_06A032 3.
Page 603 6A-14 DISASSEMBLY AND REASSEMBLY Disassembly 1. Remove the steering column assembly. Notice Be careful not to impact the steering column and steering column shaft. Otherwise, the plastic sleeve may be broken in case of frontal colliding. Y220_06A035 2. Remove the steering column shaft from steering column. 1) Remove the retainer ring.
Page 604 6A-15 TROUBLE DIAGNOSIS Symptom Cause Action Noise (When operating the Loosened steering column nuts Retightening steering wheel) Worn or damaged steering shaft bearing Replace the steering column Loosened intermediate shaft pinch bolts Retightening Excessive steering force Worn or damaged steering shaft bearing Replace the steering column Poor operation of the Internal defects in lock cylinder...
Page 605 6A-16 SPECIAL TOOLS AND EQUIPMENT Name and Part Number Application 661 589 00 33 00 (L 99 46 001 0A) Removal of steering wheel Steering wheel puller Y220_06A039 Y220_06A040 STEERING COLUMN CHANGED BY EFFECTIVE DATE REXTON SM - 2004.4 AFFECTED VIN...
Page 606 6B-1 SECTION 6B ECPS (ELECTRONIC CONTROL POWER STEERING) Table of Contents GENERAL INFORMATION ..........6B-3 Overview ..............6B-3 Input/output of ECPS control unit ......6B-4 ECPS configuration ........... 6B-4 Solenoid valve ............6B-5 ECPS control unit ............6B-6 System control ............6B-7 TROUBLE DIAGNOSIS ..........
Page 607 6B-3 GENERAL INFORMATION OVERVIEW In traditional constant power assist steering system, the steerability gets lighter as vehicle speed rises, and this may cause dangerous situation. Where as having heavy steerability in high speed driving makes it difficult to manipulate the steering wheel when vehicle is in stop.
Page 608 6B-4 INPUT/OUTPUT OF ECPS CONTROL UNIT IG Power Solenoid Valve Ground ECPS Meter cluster (SSPS warning lamp) CONTROL UNIT CAN HIGH Trouble Diagnosis CAN LOW ECPS CONFIGURATION Pinion valve Valve body Spring Balance line Right Filter cylinder Spool Pressure Connector Left cylinder Solenoid valve...
Page 609 6B-5 SOLENOID VALVE ECPS control unit controls the amount of electric current to solenoid valve according to the vehicle speed. In other words, the solenoid valve controls the hydraulic pressure applied to reaction plunger by changing the valve spool position that is linked with solenoid valve according to the amount of electric current.
Page 610 6B-6 2. In medium and high speed driving Solenoid valve Hydraulic pressure (supply) Return port Inlet port Y220_06B004 1. The shaft operation force of solenoid rod is reduced due to the reduction of output current from ECPS control unit. 2. The coil spring pulls the PCV spool toward solenoid valve to open it. 3.
Page 611 6B-7 SYSTEM CONTROL ECPS system, according to the vehicle speed, enables to achieve proper steering characteristics by controlling hydrau- lic pressure to reaction plunger located in input shaft of power steering gear box. In other words, ECPS control unit enhances the parking conveniences by controlling duty type current control.
Page 612 6B-8 2. During high speed driving During high speed driving, the control unit supplies weak electric current to solenoid valve. Then, the spool located PCV moves from top to bottom, and the working pressure (A port) from oil pump is applied to reaction plunger (C port ) through B port.
Page 613 6B-9 TROUBLE DIAGNOSIS POWER STEERING SOLENOID VALVE Location ECPS solenoid valve ECPS solenoid valve Y220_06B010 Electric Current Check ECPS solenoid valve 1. Disconnect the solenoid valve connector (waterproof connector) and install the ammeter between solenoid valve connector and wiring harness. Notice Do not ground the solenoid terminal.
Page 614 6B-10 2. When the vehicle speed is at 0 km/h, check whether the electric current for solenoid is in specified range and check that the current is reduced as the vehicle speed increases. 0.9 ~ 1.1 A Current (vehicle Speed at 0 km/h) Vehicle speed [km/h] Y220_06B012 ECPS (Electronic Control Power Steering)
Page 615 6B-11 FLOW CHART FOR TROUBLE DIAGNOSIS Note 1. Use a scanner to check. 2. Refer to circuit diagram for ECPS ECU. Any problem with ECU Open wiring (damaged harness) Repair harness/replace fuse power supply fuse? Check ignition switch with ECU Reconnect or repair harness.
Page 616 6B-12 FAIL SAFE FUNCTION Detecting Trouble Trouble Trouble Condition Action Description Time Code Over voltage > 17 V 1 sec C1101 Solenoid current: 0 A 10 V<V <16 V Low voltage < 8 V 1 sec C1102 Solenoid current: 0 A 10 V<V <16 V Input signal of...
Page 617 6B-13 CIRCUIT DIAGRAM S.S.P.S (SPEED SENSITIVE POWER STEERING) Y220_06B013 ECPS (Electronic Control Power Steering) CHANGED BY REXTON SM - 2004.4 EFFECTIVE DATE AFFECTED VIN...
Page 618 6B-14 REMOVAL AND INSTALLATION OF ECPS CONTROL UNIT The ECPS control unit is installed on the hydraulic jack mounting bracket in luggage compartment. Notice Overhaul and separate part changing is not allowed. Thus, even though the fault is only in the ECPS related system likes solenoid valve, you must replace the power steering assembly.
Page 619 6C-1 SECTION 6C POWER STEERING Table of Contents GENERAL INFORMATION ..........6C-3 Overview ..............6C-3 Specifications ............. 6C-4 Component locator ............ 6C-5 REMOVAL AND INSTALLATION ........6C-7 Removal ..............6C-8 Installation ..............6C-11 DISASSEMBLY AND REASSEMBLY ......6C-14 Disassembly ............. 6C-14 Reassembly .............
Page 620 6C-3 GENERAL INFORMATION OVERVIEW This chapter describes the basic power steering system Power Steering Gear Assembly without ECPS installed in Rexton. The power steering system consists of pump, oil reservoir, rack and pinion gear. The power steering pump is a vane type and delivers hydraulic pressure to operate the power steering system.
Page 621 6C-4 SPECIFICATIONS Description Specification Steering wheel Type 4-spoke type Outer diameter (mm) Steering gear box Type Rack and pinion Gear ratio Steering angle Inner 36° 17 Outer 32° 40 Oil pump Type Vane type Maximum pressure (kgf/cm 85 ~ 92 Displacement ( /min) 10.5...
Page 622 6C-5 COMPONENT LOCATOR System Layout Y220_06C002 A. Installation point 1. Steering components POWER STEERING CHANGED BY REXTON SM - 2004.4 EFFECTIVE DATE AFFECTED VIN...
Page 623 6C-6 Sectional View of Steering Gear Box Y220_06C003 1. Tie rod end 7. Tie rod end 2. Tie rod 8. Tie rod 3. Bellows 9. Cylinder tube 4. Rack housing 10. Valve assembly 5. Feed tube 11. ECPS solenoid valve 6.
Page 624 6C-7 REMOVAL AND INSTALLATION Y220_06C004 1. Power steering pump reservoir assembly 8. Hexagon bolt 2. Power steering pump cap assembly 9. Fan screw (M5) 3. Clip 10. Welded nut 4. Return line 11. Pipe clamp 5. Pressure line 12. Hexagon bolt 6.
Page 625 6C-8 REMOVAL Power Steering Pipe and Hose 1. Remove the supply pipe (1) and return hose (2) from the power steering pump. Notice Collect the spilled oil with a proper container. Y220_06C005 2. Remove the supply pipe and return pipe from the power steering gear box.
Page 626 6C-9 Power Steering Gear Box 1. Remove the tie rod from steering knuckle. Remove the split pin and slotted nut from tie rod end and pull off the tie rod by using special tool. Y220_06C007 2. Unscrew the joint blots in steering lower shaft and remove the lower shaft and gear box.
Page 627 6C-10 4. Unscrew the clamping bolts and remove the steering gear box assembly. Y220_06C011 Steering Gear Pump 1. Remove the drive belt from pump pulley with the pipes and hoses disconnected. Y220_06C013 2. Unscrew the bolts and nuts, and remove the pump assembly (reservoir integrated type).
Page 628 6C-11 INSTALLATION Check the removed components for wear, crack and damage. Replace or repair the defective components. 1. Install the power steering pump to the engine. Upper bolts 23 Nm Lower bolts 23 Nm Y220_06C056 2. Install the power steering gear box to the frame and temporarily tighten the mounting bolts.
Page 629 6C-12 4. Install the steering lower shaft to the gear box. The joint bolt should be inserted from “A” (no threaded side) to “B” (threaded side). Tightening torque 25 ~ 30 Nm Notice The joint bolt (1) should be inserted the groove in pinion shaft spline when installing the lower shaft.
Page 630 6C-13 8. Connect the return hose (2) to the steering gear pump reservoir and install the spring clamp. 9. After installation, bleed the air from the system. Notice Fully insert the hose to the reservoir and locate the spring clamp at the center of the nipple. Y220_06C020 POWER STEERING CHANGED BY...
Page 631 6C-14 DISASSEMBLY AND REASSEMBLY DISASSEMBLY * describes the basic power steering assembly. 1. Remove the tie rod end boot (a). Y220_06C021 2. Remove the feed lines (2) from the cylinder tube in gear box. 3. Remove the feed lines (1) from the valve housing in gear box.
Page 632 6C-15 5. Remove the dust cover (1) and retainer ring (2). Y220_06C024 6. Remove the pinion dust cover (lower, 3) and unscrew the pinion lock nut (4). Notice Before removing the pinion lock nut, make sure to lock the pinion gear to prevent it from damaging. Y220_06C025 7.
Page 633 6C-16 9. Remove the pinion shaft seal (7), needle bearing (8) and retaining ring (9). Notice Do not disassemble the power steering gear housing and rack gear. Replace it as an assembly if needed. Y220_06C028 POWER STEERING CHANGED BY EFFECTIVE DATE REXTON SM - 2004.4 AFFECTED VIN...
Page 634 6C-17 REASSEMBLY 1. Install the steering pinion gear. 1) Install the retaining ring. 2) Install the needle bearing. 3) Install the pinion shaft seal by tapping it with a long and flat end drift. Y220_06C029 2. Tighten the steering pinion lock nut (4) with a specified tightening torque.
Page 635 6C-18 4. Install the rack bearing. • Install the adjusting spring. • Tighten the adjusting plug with a specified tightening torque. • Tighten the lock nut. • Adjust the preload of steering gear. Y220_06C032 5. Install the hydraulic pipes. Y220_06C033 6.
Page 636 6C-19 INSPECTION Rack Gear Shaft 1. Check the rack gear for deformation and damage. • Place the V-blocks (1) on the flatten plate. • Put the rack gear (2 and 4) on the V-blocks. • Measure the straightness of rack gear with a dial gauge.
Page 637 6C-20 5. Check the tie rod end and the tie rod ball joint for damage. • Check the tie rod end ball joint for operation. • Check the tie rod ball joint for operation. Check the tie rod for deflection due to its weight. 6.
Page 638 6C-21 TROUBLE DIAGNOSIS Symptom Cause Action Hard steering Lack of lubrication Lubricate Abnormal wear or binding of steering ball joint Replace Damaged or faulty steering gear Replace gear assembly Improper preload of steering pinion Adjust Faulty steering shaft joint Replace Steering fluid leaks Repair or replace Lack of fluid or air-in system...
Page 639 6C-22 GENERAL INSPECTION POWER STEERING GEAR PRELOAD ADJUSTMENT 1. Place the steering wheel at straight ahead direction. 2. Lift up the vehicle very carefully. 3. Remove the adjusting plug lock nut. 4. Measure the torque of adjusting plug. Y220_06C043 5. If the measured torque is out of range, adjust it to the specified value.
Page 640 6C-23 STEERING EFFORT CHECK 1. Park the vehicle on a paved and flat ground and place the front wheels at straight ahead direction. 2. Start the engine and let it run around 1,000 rpm. 3. Install the spring scale on the circumference of the steering wheel and measure the steering effort in both directions.
Page 641 6C-24 OIL PUMP PRESSURE Check the oil pump pressure to locate any defect in oil pump. Notice Before checking the pressure, check the oil level and belt tension. Prepare the empty container to collect the spilled oil during the service. 1.
Page 642 6C-25 OIL LEVEL CHECK The power steering oil level have to be checked by two conditions; one is checked at normal operating temperature, and the other one is checked when it is cooled. If the differ- ence between two measurements is below 5 mm and the level is between Max and Min level, it’s normal.
Page 643 6C-26 AIR BLEEDING The air bleeding should be done after servicing the power steer- ing system and when the difference between two measure- ments (cooled and normal temperature) is prominent. 1. Lift up the vehicle very carefully. 2. Turn the steering wheel to its both ends several times and add the oil up to MAX line in the steering oil reservoir.
Page 644 6C-27 SPECIAL TOOLS AND EQUIPMENT Name and Part Number Application 661 589 13 33 00 Removal of the upper and lower end assemblies of front Ball joint puller suspension Y220_06C054 Y220_06C055 POWER STEERING CHANGED BY REXTON SM - 2004.4 EFFECTIVE DATE AFFECTED VIN...
Page 645 MEMO ..................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................
Page 646 SECTION SUSPENSION SYSTEM CONTENTS FRONT SUSPENSION ..........7A REAR SUSPENSION............. 7B...
Page 647 7A-1 SECTION 7A FRONT SUSPENSION Table of Contents GENERAL INFORMATION ..........7A-3 Overview ..............7A-3 Specifications ............. 7A-5 System layout ............. 7A-6 Sectional view of shock absorber assembly ..... 7A-7 REMOVAL AND INSTALLATION ........7A-8 Stabilizer ..............7A-10 Shock absorber assembly ........7A-12 Upper arm and lower arm assembly ......
Page 648 7A-3 GENERAL INFORMATION OVERVIEW Coil Spring Description and Operation of Front Suspension The coil spring is made by winding solid steel rod to form the coil shape. Its energy absorption rate per weight is higher The suspension is the device to connect the axle and ve- than that of the leaf spring and it allows to absorb small hicle frame.
Page 649 7A-4 Upper Arm and Lower Arm Assembly The shock absorber is mounted to the upper arm and the lower arm with bushings. The upper arm relieves the load delivered from spring, shock absorber and bumper. The lower arm relieves the load to knuckle. This enables to absorb the various impacts according to the load shapes and to ensure the drivability.
Page 650 7A-5 SPECIFICATIONS Description Specification Suspension type Double wishbone Spring type Coil spring Shock absorber type Cylindrical double tube (gas type) Stabilizer type Torsion bar Wheel alignment Toe-in 2 ± 2 mm Camber 0° ± 30° (the difference between both ends is should be below 30°) Caster 3°...
Page 651 7A-6 SYSTEM LAYOUT Components Locator Y220_07A005 1. Stabilizer bar 5. Stabilizer bar link 2. Cam bolt 6. Knuckle 3. Lower arm 7. Upper arm 4. Yoke 8. Shock absorber assembly (including coil spring) FRONT SUSPENSION CHANGED BY EFFECTIVE DATE REXTON SM - 2004.4 AFFECTED VIN...
Page 652 7A-7 SECTIONAL VIEW OF SHOCK ABSORBER ASSEMBLY Y220_07A007 1. Lower spring seat 7. Spring 13. Rubber 2. Yoke bracket 8. Yoke 14. Rubber 3. Rebound stopper 9. Boot 15. Spacer 4. Cylinder 10. Bumper stopper 16. Washer 5. Piston 11. Spring seat rubber 17.
Page 653 7A-8 REMOVAL AND INSTALLATION Y220_07A008 FRONT SUSPENSION CHANGED BY EFFECTIVE DATE REXTON SM - 2004.4 AFFECTED VIN...
Page 654 7A-9 1. Nut 15. Nut 2. Nut 16. Bolt 3. Washer 17. Bolt 4. Rubber 18. Bolt 5. Bushing 19. Bushing 6. Upper spring seat 20. Nut 7. Rubber 21. Upper arm 8. Spring seat rubber 22. Nut 9. Boot 23.
Page 655 7A-10 STABILIZER Removal 1. Remove the under cover (skid plate). Y220_07A009 2. Remove the upper mounting nut (1) and the lower mounting nut (2) from the front stabilizer bar link. Remove the front stabilizer bar link. Y220_07A010 3. Unscrew the mounting cap bolts and remove the front stabilizer bar.
Page 656 7A-11 Installation 1. Install the front stabilizer bar to the frame Mounting cap bolt 60 ~ 80 Nm Y220_07A012 2. Install the stabilizer bar link to the stabilizer and the lower arm. (1) 110 ~ 120 Nm Tightening torque (2) 110 ~ 130 Nm Y220_07A013 3.
Page 657 7A-12 SHOCK ABSORBER ASSEMBLY Removal 1. Remove three upper nuts from shock absorber assembly. Y220_07A015 2. Unscrew the nut and remove the shock absorber yoke lock pin from lower arm. Y220_07A016 3. Unscrew the nuts and separate the lower yoke from coil spring assembly.
Page 658 7A-13 Installation 1. Install the coil spring (shock absorber) assembly and yoke. To do this, arrange the bottom of the shock absorber to yoke clevis and insert the top of it into the bolt hole, and temporarily tighten the nut by hand. Tightening torque 40 ~ 60 Nm Y220_07A019...
Page 659 7A-14 UPPER ARM AND LOWER ARM AS- SEMBLY Removal Preceding works: • Remove the shock absorber assembly. • Remove the steering knuckle (refer to Steering section). 1. Remove the slotted nuts and split pins from the upper arm joint and the lower arm joint. Note Use only the special tool as shown in figure to separate the ball joint and steering knuckle.
Page 660 7A-15 Installation 1. Install the lower arm to the frame bracket. Notice • Insert the bolts from rear side of vehicle. • Align the center scale of the bolt to the mark on the bracket. Tightening torque 180 ~ 190 Nm Y220_07A025 2.
Page 661 7A-16 DISASSEMBLY AND ASSEMBLY FRONT COIL SPRING Disassembly 1. Remove the front coil spring assembly. 2. Compress the coil spring coil assembly with a special tool as shown in figure. Notice Securely install the coil spring with the special tool. Do not let the spring end face to your body while compressing it.
Page 662 7A-17 Reassembly 1. Compress the coil spring to the specified length, assemble all components and tighten the lock nut. Compressed length 344 mm Tightening torque of lock nut 25 ~ 40 Nm Notice 1. Make sure to install the coil spring in correct direction.
Page 663 7A-18 HUB AND BEARING Disassembly and Reassembly (Part time TC) 1. Remove the front hub and bearing assembly. 2. Remove the outer bearing (1) and inner seal. Installation Notice Replace the oil seal with new one. 3. Remove the inner bearing (2). Y220_07A034 4.
Page 664 7A-19 Installation Notice • Install the outer bearing race with a outer bearing race installer and handle. Y220_07A037 • Install the inner bearing race with a inner bearing race installer and handle. 6. Reassemble in the reverse order of disassembly. Y220_07A038 FRONT SUSPENSION CHANGED BY...
Page 665 7A-20 TROUBLE DIAGNOSIS Symptom Cause Action Vehicle rolling Broken stabilizer bar Replace Faulty shock absorber Replace Abnormal noises Loosening mountings Re-tighten Damaged or worn wheel bearing Replace Damaged shock absorber Replace Damaged tire Replace Poor riding Over inflated tire Pressure adjust Faulty shock absorber Replace Loosened wheel nut...
Page 666 7A-21 SPECIAL TOOLS AND EQUIPMENT Name and Part Number Application Removal and installation of hub SY 340 - 050 (W 99 48 009 0A) Sliding hammer Y220_07A039 Y220_07A040 Removal and installation of front SY 340 - 060 (W 99 48 010 0A) hub cap Front hub cap remover/installer Using with SY340-050 (sliding...
Page 667 7A-22 Name and Part Number Application Removal of upper and lower end 661 589 13 33 00 (W 99 44 002 0A) assembly from front suspension Ball joint puller Y220_07A047 Y220_07A048 Removal and installation of front SY 340 - 021 - 01 (W 99 48 006 0A) bearing Handle Y220_07A049...
Page 668 7A-23 Name and Part Number Application Removal and installation of front SY 310 - 010 (Y 99 44 001 0A) coil spring Front coil spring remover and installer Y220_07A055 Y220_07A056 FRONT SUSPENSION CHANGED BY REXTON SM - 2004.4 EFFECTIVE DATE AFFECTED VIN...
Page 669 MEMO ..................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................
Page 670 7B-1 SECTION 7B REAR SUSPENSION Table of Contents GENERAL INFORMATION ..........7B-3 Overview ..............7B-3 Specifications ............. 7B-4 SYSTEM LAYOUT ............7B-5 Rear suspension assembly ........7B-5 REMOVAL AND INSTALLATION ........7B-6 TROUBLE DIAGNOSIS ..........7B-14 INSPECTION ..............7B-15 Wheel bearing end play .......... 7B-15 Wheel bearing preload ..........
Page 671 7B-3 GENERAL INFORMATION OVERVIEW The rear suspension is also to keep the ride comforts 1. Stabilizer: and drivability and this vehicle uses 5-link suspension It maintains the balance of the vehicle when turning, and system. It consists of coil springs on both sides, up- minimizes the vehicle’s slope when the wheels are moving per and lower arm, lateral rod, stabilizer, connecting up and down separately.
Page 672 7B-4 SPECIFICATIONS Description Specification Suspension type 5-Link type (2 upper arms, 2 lower arms, 1 lateral rod) Spring type Coil spring Stabilizer type Torsion bar Shock absorber Type Cylindrical double tube Max. length 495 mm 308 mm Min. length Engine Gasoline 3.2, Diesel (A/T) Coil spring 13.1 mm...
Page 673 7B-5 SYSTEM LAYOUT REAR SUSPENSION ASSEMBLY Y220_07B003 1. Coil spring seat (upper) 6. Lower arm (link) 2. Coil spring 7. Stabilizer link 3. Lateral rod 8. Stabilizer 4. Shock absorber 9. Bumper stopper 5. Upper arm (link) REAR SUSPENSION CHANGED BY REXTON SM - 2004.4 EFFECTIVE DATE AFFECTED VIN...
Page 674 7B-6 REMOVAL AND INSTALLATION Y220_07B005 1. Rear suspension assembly 6. Stabilizer 2. Rubber 7. Coil spring 3. Upper arm 8. Shock absorber 4. Lower arm 9. Lateral rod 5. Stabilizer link REAR SUSPENSION CHANGED BY EFFECTIVE DATE REXTON SM - 2004.4 AFFECTED VIN...
Page 675 7B-7 Removal 1. Support the rear axle housing with a jack and place the blocks under the wheels. Y220_07B006 2. Remove the mounting nut at the lower link and separate the stabilizer bar. Y220_07B007 3. Unscrew the mounting cap bolts at both sides and remove the stabilizer bar and bushings.
Page 676 7B-8 5. Remove the lateral rod mounting bolts on frame. Y220_07B010 6. Unscrew the lateral rod mounting bolts on axle and remove the rod assembly. Y220_07B011 7. Remove the lower nut of shock absorber. Y220_07B012 8. Unscrew the upper nut and remove the shock absorber. Y220_07B013 REAR SUSPENSION CHANGED BY...
Page 677 7B-9 9. Remove the upper arm bolt and nut on frame. Y220_07B014 10. Unscrew the upper bolt and nut on axle and remove the upper arm. Y220_07B015 11. Remove the lower arm connected to frame. Y220_07B016 12. Unscrew the lower arm bolt and nut on axle and remove the lower arm.
Page 678 7B-10 13. Disconnect the brake pipes and hoses and remove the spring while rocking the rear axle. 14. Unscrew the shock absorber lower nut and the upper arm bolt on axle and remove the spring through the space between frame and rear axle. Y220_07B018 REAR SUSPENSION CHANGED BY...
Page 679 7B-11 Installation 1. Install in the reverse order of removal. 2. Place the spring on the its installation position. Notice 1. The top side of the spring is larger than the bottom side of it. 2. The coil spring should be securely seated between the spring seat on axle and the spring seat in frame.
Page 680 7B-12 5. Install the lower arm. Frame 1 Tightening torque 165 Nm Axle 2 Tightening torque 165 Nm Y220_07B022 6. Install the lateral rod. Frame 1 Tightening torque 165 Nm Axle 2 Tightening torque 165 Nm Y220_07B023 7. Install the connecting rod to frame bracket. Tightening torque 38 Nm Distance (A)
Page 681 7B-13 9. Install the rubbers (packings) with correct order. Notice Replace the cracked or worn rubbers with new ones. 10. Check the shock absorber for leak and abnormal noise. Y220_07B026 Notice Before disposal, fully extend the shock absorber and drill out a hole in “A” range to discharge the internal gas.
Page 682 7B-14 TROUBLE DIAGNOSIS Symptom Cause Action Vehicle rolling Broken stabilizer bar Replace Faulty shock absorber Replace Abnormal noises Loosening mountings Re-tighten Damaged or worn wheel bearing Replace Damaged shock absorber Replace Damaged tire Replace Poor riding Over inflated tire Pressure adjust Faulty shock absorber Replace Loosened wheel nut...
Page 683 7B-15 INSPECTION WHEEL BEARING END PLAY 1. Release the parking brake. 2. Raise the rear wheel. 3. Check if the wheel bearing end play exists while rocking the wheel. End play 0 mm 4. If the end play exists, retighten the slotted nut. 5.
Page 684 7B-16 SPECIAL TOOLS AND EQUIPMENT Name and Part Number Application Removal and installation of rear sus- 661 589 12 33 00 (Y 99 45 001 0A) pension Coil spring compressor Y220_07B030 Y220_07B031 REAR SUSPENSION CHANGED BY EFFECTIVE DATE REXTON SM - 2004.4 AFFECTED VIN...
Page 685 SECTION BRAKE SYSTEM CONTENTS BRAKE SYSTEM ............8A FRONT BRAKE ............. 8B REAR BRAKE..............8C PARKING BRAKE............8D ABS ................8E1 ESP SYSTEM .............. 8E2...
Page 686 8A-1 SECTION 8A BRAKE SYSTEM Table of Contents GENERAL INFORMATION ..........8A-3 Description and operation ......... 8A-3 System layout (hydraulic line) ........8A-5 COMPONENTS LOCATOR ..........8A-6 Brake system ............. 8A-6 Master cylinder and booster ........8A-8 INSPECTION ..............8A-9 REMOVAL AND INSTALLATION ........
Page 687 8A-3 GENERAL INFORMATION DESCRIPTION AND OPERATION Brake Pedal Brake System Even though a driver cuts off the power, while driving, the vehicle continues to move due to the law of inertia. Therefore, a braking device is needed to stop the vehicle. The brake system normally uses the frictional discs that converts the kinetic energy to the thermal energy by fric- tional operation.
Page 688 8A-4 Brake Booster The brake booster is a power assist device for brake system. It relieves the pedal depressing force by using the pressure difference between the vacuum pressure gen- erated by vacuum pump in intake manifold and the atmo- spheric pressure.
Page 689 8A-5 SYSTEM LAYOUT (HYDRAULIC LINE) With ABS Without ABS Y220_08A006 1. Brake booster 5. Load conscious reducing valve (LCRV) 2. Brake reservoir and master cylinder 6. 3-way connector 3. ABS control unit 7. Rear drum (disc) and wheel cylinder (caliper) 4.
Page 690 8A-6 COMPONENTS LOCATOR BRAKE SYSTEM Y220_08A007 BRAKE SYSTEM CHANGED BY EFFECTIVE DATE REXTON SM - 2004.4 AFFECTED VIN...
Page 691 8A-7 1. Brake booster 13. Stop lamp switch 2. Brake booster boot 14. Pedal assembly 3. Cotter pin 15. Pedal bracket assembly 4. Clevis 16. Brake pedal pad 5. Clevis pin 17. Brake pedal 6. Packing (1) 18. Brake pedal spring 7.
Page 692 8A-8 MASTER CYLINDER AND BOOSTER Without ABS With ABS and ABD With ESP Y220_08A008 1. Reservoir 4. Push rod 2. Master cylinder 5. Pressure sensor 3. Booster BRAKE SYSTEM CHANGED BY EFFECTIVE DATE REXTON SM - 2004.4 AFFECTED VIN...
Page 693 8A-9 INSPECTION Air Bleeding (With ABS) 6. Repeat the step 4 through 5 until clear brake fluid comes out of air bleed screw. 7. Perform the same procedures at each wheel. Notice Repeat the step 4 through 5 until clear brake fluid comes out of air bleed screw.
Page 694 8A-10 After Replacing Master Cylinder 1. Add oil after replacing the master cylinder. 2. Pump the brake pedal several times until the hydraulic pressure is generated. Then, keep the pedal depressing. 3. Loosen the pipe screw at the outlet port in master cylinder to bleed the air.
Page 695 8A-11 REMOVAL AND INSTALLATION BRAKE BOOSTER VACUUM HOSE Removal 1. Disconnect the vacuum hose from brake booster. Y220_08A010 2. Disconnect the vacuum hose from vacuum pump. Y220_08A011 3. Disconnect the vacuum hose from vacuum modulator. 4. Remove the vacuum hose with vacuum hose bracket. Y220_08A012 5.
Page 696 8A-12 BRAKE FLUID LEVEL SWITCH Removal and Installation 1. Disconnect the brake fluid level switch connector. Y220_08A015 2. Disconnect the switch from brake fluid reservoir. Y220_08A016 * ESP equipped vehicle 3. Install in the reverse order of removal. BRAKE SYSTEM CHANGED BY EFFECTIVE DATE REXTON SM - 2004.4...
Page 697 8A-13 BRAKE FLUID RESERVOIR Removal and Installation 1. Open the reservoir cap and drain the oil. 2. Remove the brake fluid reservoir. Notice 1.Do not apply excessive force when removing the reservoir. 2.Incase of the reservoir equipped vehicle, pull out the lock pin (2) and remove the reservoir.
Page 698 8A-14 MASTER CYLINDER Removal Preceding work: Drain the oil. 1. Disconnect the master cylinder connector. Y220_08A018 2. Disconnect the brake pipes from master cylinder. Notice Be careful not to splash the brake fluid on painted area. If splashed, immediately clean the affected area. Y220_08A019 3.
Page 699 8A-15 Installation 1. Install the assembled master cylinder to booster. Tightening torque 8 ~ 12 Nm Y220_08A021 2. Install the brake pipes to master cylinder. Tightening torque 15 ~ 18 Nm 3. Engage the master cylinder connector. 4. Bleed the air from the brake system. Y220_08A022 BRAKE SYSTEM CHANGED BY...
Page 700 8A-16 BRAKE BOOSTER Removal and Installation Preceding work: Drain the oil. 1. Remove the master cylinder assembly and pull out the cotter pin from brake booster push rod. 2. Remove the clevis pin. Y220_08A028 3. Remove the booster mounting nuts. Y220_08A029 4.
Page 701 8A-17 STOP LAMP SWITCH Removal and Installation 1. Disconnect the negative battery cable. 2. Disconnect the stop lamp switch connector. Y220_08A031 3. Unscrew the stop lamp switch nuts and remove the switch. Y220_08A032 4. Install in the reverse order of removal. Tightening torque 21 ~ 35 Nm Y220_08A033...
Page 702 8A-18 BRAKE PEDAL Removal and Installation 1. Unscrew the brake pedal bolts and nuts and remove the cotter pin. Y220_08A034 2. Remove the brake pedal assembly. 1. Brake pedal 2. Return spring 3. Bushing 4. Stopper 5. Brake pedal pad Y220_08A035 3.
Page 703 8A-19 BRAKE HOSE/PIPE Removal 1. Remove the brake pipes. • Remove the pipes and pressure sensor from master cylinder. Y220_08A037 • In case of ABS/ESP equipped vehicle, remove the pipes from control unit. Y220_08A038 • Remove the pipes from 3-way connector and remove the brackets for connecting pipes.
Page 704 8A-20 Installation 1. Engage the rear brake hose and tighten the union bolt. Tightening torque 20 ~ 30 Nm Y220_08A042 2. Engage the front brake hose and tighten the union bolt. Tightening torque 20 ~ 30 Nm Y220_08A043 3. Install the brake pipes at correct positions. 3-way connector 15 ~ 19 Nm ABS/ABD control unit...
Page 705 8A-21 BRAKE PEDAL CHECK Pedal Height / Maximum Stroke Check the brake pedal with below procedures: 1. Start the engine. 2. Depress the brake pedal around 3 times. 3. Depress the brake pedal with approx. 30 kg and measure the distance (A) between the upper surface of pedal pad and the lower dash panel.
Page 706 8A-22 STOP LAMP SWITCH CHECK Connect the multimeter to stop lamp switch connector and check if the continuity exists when pushing in the plunger. If the continuity doesn’t exist, the stop lamp switch is normal. No continuity Continuity Plunger Y220_08A052 BRAKE BOOSTER CHECK 1.
Page 707 8A-23 TROUBLE DIAGNOSIS Symptom Cause Action Incorrectly mounted back plate or caliper Repair Noise or vehicle vibration when applied Loosened bolt of back plate or caliper Retighten Crack or uneven wear of brake drum or disc Replace Foreign material inside the brake drum Clean Pad or lining sticking to contact surface Replace...
Page 708 MEMO ..................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................
Page 709 8B-1 SECTION 8B FRONT BRAKE Table of Contents GENERAL INFORMATION ..........8B-3 Description and operation ......... 8B-3 Specifications ............. 8B-3 REMOVAL AND INSTALLATION ........8B-4 Front brake ..............8B-5 INSPECTION ..............8B-8 Pad thickness ............. 8B-8 Brake disc thickness ..........8B-8 Brake disc run-out .............
Page 710 8B-3 GENERAL INFORMATION DESCRIPTION AND OPERATION Caliper Adjustment of Clearance The disc brake is normally used for front wheels, however, When the hydraulic pressure is applied to the piston, the currently it is also used for rear wheels. The floating cali- piston moves to push the pad.
Page 711 8B-4 REMOVAL AND INSTALLATION Y220_08B003 1. Brake caliper assembly 5. Caliper mounting bolt 2. Guide rod set 6. Piston seal 3. Brake pad 7. Piston 4. Brake pad spring 8. Caliper FRONT BRAKE CHANGED BY EFFECTIVE DATE REXTON SM - 2004.4 AFFECTED VIN...
Page 712 8B-5 FRONT BRAKE Removal Preceding work: Remove the negative battery cable. 1. Remove the tire and disconnect the brake hose from brake caliper. Notice Be careful not to splash the oil. Y220_08B004 2. Unscrew the bolts and remove the cylinder and disc pads. Y220_08B005 3.
Page 713 8B-6 Brake Pad Change 1. Unscrew the bolts at bottom side of brake caliper cylinder. Y220_08B008 2. Swing up the caliper cylinder assembly and hold it not to damage the hose. Y220_08B009 3. Remove the brake pads and replace them with new ones. 4.
Page 714 8B-7 Installation Full-time 1. Place the front disc assembly to the knuckle and tighten the lock nut with the specified value. (Full-time 4WD) 2. Place the disc, locking hub and hub range and tighten the mounting bolts. (Part-time 4WD) Part-time Y220_08B012 3.
Page 715 8B-8 INSPECTION Clean the dissembled components and visually check the followings: • Wear, rust and damage on the cylinder and piston • Damage, crack and wear on cylinder body and guide pin • Uneven wear and oil contamination on boot •...
Page 716 8B-9 BRAKE DISC RUN-OUT 1. Install the dial gauge on the side of brake disc and measure the run-out while rotating the brake disc. 2. If the measured value exceeds the limit, replace the brake disc with new one. Otherwise, it may cause the pedal vibration and shimmy when braking.
Page 717 8B-10 TROUBLE DIAGNOSIS Symptom Cause Action Poor braking Pad wear, hardening Replace Oil or water contamination on the pad Replace and repair Inoperative caliper Replace Uneven braking Pad wear, hardening Replace Oil or water contamination on the pad Replace and repair Uneven wear or twisted of the disc Replace Inoperative caliper...
Page 718 8B-11 SPECIAL TOOLS AND EQUIPMENT Name and Part Number Application 661 589 16 33 00 (W 99 48 002 0A) Removal of ABS front brake tooth wheel Front ABS tooth wheel puller Y220_08B019 Y220_08B020 661 589 17 33 00 (W 99 48 003 0A) Installation of ABS front brake tooth wheel Front ABS tooth wheel installer...
Page 719 MEMO ..................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................
Page 720 8C-1 SECTION 8C REAR BRAKE Table of Contents GENERAL INFORMATION ..........8C-3 Description and operation ......... 8C-3 Disc brake ..............8C-4 Specifications ............. 8C-5 COMPONENTS LOCATOR ..........8C-6 Disc brake ..............8C-6 REMOVAL AND INSTALLATION ........8C-7 Disc brake ..............8C-7 Drum brake ..............
Page 721 8C-3 GENERAL INFORMATION DESCRIPTION AND OPERATION Drum Brake Brake lining and drum clearance automatic control system This drum brake assembly is a leading/trailing shoe design. If the lining’s wear is excessive, the piston moves to long distance and the pedal travel increases. The clearance Brake Drum between the drum and the brake lining should be adjusted.
Page 722 8C-4 Brake Lining DISC BRAKE The disc brake is normally used for front wheels, however, The brake lining is installed with the brake shoe and pushed currently it is also used for rear wheels. The floating cali- toward the drum for applying the brake pedal. Thus, lining per type disc brake installed in this vehicle has only one must have high-heat tolerance, abrasion resistance and brake cylinder at one side of caliper.
Page 723 8C-5 SPECIFICATIONS Description Drum Brake Disc Brake φ Inner diameter of drum 254 mm Shoe Type Leading and trailing Lining width x Length x Thickness 55 X 243 X 4.7 mm φ Inner diameter of wheel cylinder 23.81 mm φ Inner diameter of caliper cylinder 42.9 mm Brake pad thickness...
Page 724 8C-6 COMPONENTS LOCATOR DISC BRAKE Y220_08C007 1. Backing plate 5. Disc 2. Parking cable 6. Wheel 3. Parking cable lever 7. Air bleeder nipple 4. Caliper assembly 9. Shaft assembly REAR BRAKE CHANGED BY EFFECTIVE DATE REXTON SM - 2004.4 AFFECTED VIN...
Page 725 8C-7 REMOVAL AND INSTALLATION DISC BRAKE Y220_08C008 1. Rear brake disc assembly 6. Gasket ............replace 2. Brake pad 7. Brake hose 3. Brake caliper 8. Gasket ............replace 4. Gasket ............replace 9. Eye hose bolt ..........8 ~ 18 Nm 5.
Page 726 8C-8 Removal 1. Remove the rear tire. Notice • Park the vehicle on the flat and even ground and set the blocks under the front tires. • Release the parking brake. • Place the shift lever to “N” (A/T) or “NEUTRAL” (M/T) position.
Page 727 8C-9 6. Separate the parking brake lining by tapping it with rubber hammer and pull it up to remove. Y220_08C015 REAR BRAKE CHANGED BY REXTON SM - 2004.4 EFFECTIVE DATE AFFECTED VIN...
Page 728 8C-10 Inspection 1. Clean the dissembled components and visually check the followings: • Wear, rust and damage on the cylinder and piston • Damage, crack and wear on cylinder body and guide pin • Uneven wear and oil contamination on boot •...
Page 729 8C-11 Brake Pad Change 1. Unscrew the bolts at bottom side of brake caliper cylinder. 2. Swing up the caliper cylinder assembly and hold it not to damage the hose. Y220_08C018 3. Remove the brake pads and replace them with new ones. Y220_08C019 4.
Page 730 8C-12 Installation 1. Insert the parking brake lining between backing plate and flange. Tightening torque 4 ~ 8 Nm Notice Apply a proper amount of grease to the parking brake side contacting surface. Y220_08C021 2. Install the caliper to brake disc. Tightening torque 85 ~ 105 Nm Y220_08C023...
Page 731 8C-13 DRUM BRAKE Y220_08C025 1. Bleed screw 9. Upper return spring 2. Bleed screw cap 10. Brake shoe locking spring pin 3. Rear brake assembly 11. Trailing shoe 4. Rear brake plate 12. Brake shoe locking spring 5. Wheel cylinder 13.
Page 732 8C-14 Removal 1. Remove the rear tire. Notice • Park the vehicle on the flat and even ground and set the blocks under the front tires. • Release the parking brake. • Place the shift lever to “N” (A/T) or “NEUTRAL” (M/T) position.
Page 733 8C-15 5. Remove the return spring. 1) Remove the upper return spring. 2) Remove the lower return spring. 3) Remove the lever spring. 4) Remove the adjuster operating lever from the adjuster. Y220_08C030 Y220_08C031 6. Remove the pin and spring by turning the lining shoe hold down washer through plug hole in the axle shaft flange.
Page 734 8C-16 8. Separate the adjust lever from the brake lining. Y220_08C034 9. Unscrew the bolts and remove the wheel cylinder. Y220_08C035 REAR BRAKE CHANGED BY EFFECTIVE DATE REXTON SM - 2004.4 AFFECTED VIN...
Page 735 8C-17 Inspection 1. Measure the inner diameter of brake drum and replace if needed. New drum Wear limit φ φ 254 mm 255.5 mm Notice Measure the inner diameter at over two points. Y220_08C036 2. Check the contacting surface of lining and brake drum. Mark the brake drum inside using chalk and scrub the shoe and lining assembly.
Page 736 8C-18 Installation 1. Install the wheel cylinder to the backing plate. Tightening torque 8 ~ 12 Nm Y220_08C038 2. Install the both brake linings between wheel cylinder and lower anchor plate. Install the adjuster and return springs. Y220_08C039 3. Engage the parking brake cable. Y220_08C040 4.
Page 737 8C-19 5. Put the plate on the axle shaft and install the brake drum. 6. Check if the brake drum turns freely while rotating it by hand. Notice Adjust the outer diameter of linings with adjusting screw if needed. Y220_08C042 7.
Page 738 8C-20 DISASSEMBLY AND REASSEMBLY WHEEL CYLINDER 1. Remove the upper return spring and wheel cylinder. Y220_08C044 2. Disassemble the wheel cylinder. • Remove and dispose the dust boot. • Remove the piston. • Remove and dispose the piston cup. • Remove the spring assembly. •...
Page 739 8C-21 PARKING BRAKE LEVER 1. Separate the parking brake operating lever and adjuster operating lever from disassembled lining. Y220_08C047 2. Remove the lever pin (arrow) and separate the parking brake operating lever and adjuster operating lever. 3. Reassemble in the reverse order of disassembly. Y220_08C048 REAR BRAKE CHANGED BY...
Page 740 8C-22 INSPECTION DRUM BRAKE TYPE Brake Drum 1. Check the drum for crack, damage and deformation. 2. Measure the inner diameter of brake drum. New drum Wear limit φ φ 254 mm 255.5 mm • Measure the inner diameter at over two positions. Y220_08C049 Brake Lining 1.
Page 741 8C-23 DISC BRAKE TYPE Pad Thickness 1. Remove the front tires. 2. Measure the pad thickness. If the thickness is below wear limit, replace it with new one. Wear limit 2 mm Y220_08C051 Brake Disc Thickness 1. Measure the disc thickness at over four points. 2.
Page 742 8C-24 TROUBLE DIAGNOSIS Symptom Cause Action Poor braking Lining wear, hardening Replace Oil or water contamination on the lining Replace or repair Inoperative wheel cylinder Replace Inoperative clearance automatic control system Repair Uneven braking Lining wear, hardening Adjust Oil or water contamination on the lining Replace or repair Inoperative wheel cylinder Replace...
Page 743 8C-25 SPECIAL TOOLS AND EQUIPMENT Name and Part Number Application 000 589 18 31 00 (A 99 48 002 2A) Holding the brake pedal Brake pedal fixture Y220_08C054 Y220_08C055 000 589 49 37 00 (P 99 48 001 0A) Seating the brake caliper dust cap Pliers Y220_08C056 Y220_08C057...
Page 744 8C-26 Name and Part Number Application 661 589 18 33 01 (W 99 48 005 0A) Removal of rear ABS brake tooth wheel Rear ABS tooth wheel puller (using with 661 589 18 33 00) Y220_08C062 Y220_08C063 REAR BRAKE CHANGED BY EFFECTIVE DATE REXTON SM - 2004.4 AFFECTED VIN...
Page 745 8D-1 SECTION 8D PARKING BRAKE Table of Contents GENERAL INFORMATION ..........8D-3 Description and operation ......... 8D-3 Specifications ............. 8D-3 Components locator ..........8D-4 REMOVAL AND INSTALLATION ........8D-5 Parking brake ............. 8D-6 INSPECTION ..............8D-9 Checking the braking force ........8D-9 TROUBLE DIAGNOSIS ..........
Page 746 8D-3 GENERAL INFORMATION DESCRIPTION AND OPERATION Parking Brake Parking Brake Switch and Indicator The parking brake is the mechanical device to hold the vehicle. When pulling up the lever, the parking brake cable When pulling up the parking brake lever with the ignition between the lever and the rear drum brake trailing shoe ON, the parking brake indicator comes on.
Page 747 8D-4 COMPONENTS LOCATOR Y220_08D003 1. Parking brake lever 5. Cable 2. Parking brake cable bracket (rear) 6. When equipped with drum brake 3. Parking brake cable bracket (front) 7. When equipped with disc brake 4. Parking brake cable bracket (center) PARKING BRAKE CHANGED BY EFFECTIVE DATE...
Page 748 8D-5 REMOVAL AND INSTALLATION Y220_08D004 1. Parking brake lever 7. Nut 2. Parking brake indicator switch 8. Bolt 3. Bolt 9. Rear parking brake cable 4. Bolt 10. Brake disc (when equipped with rear disc brake) 5. Front parking brake cable 11.
Page 749 8D-6 PARKING BRAKE Removal 1. Remove the console assembly. Y220_08D005 2. Disconnect the parking brake indicator switch. Y220_08D006 3. Disconnect the parking brake cable from parking brake lever with the parking braked released. Y220_08D007 4. Unscrew the bolts and remove the parking brake lever. 5.
Page 750 8D-7 Installation 1. Engage the parking brake cable to parking brake lever. 2. Install the bracket with parking brake cable to body. Tightening torque 8 ~ 18 Nm Y220_08D009 3. Install the parking brake lever assembly. Tightening torque 8 ~ 18 Nm Y220_08D010 4.
Page 751 8D-8 6. If it needs excessive force (notch), adjust the tension at the equalizer where both cables are combined. 7. Install the console assembly and perform the brake test. Y220_08D013 PARKING BRAKE CHANGED BY EFFECTIVE DATE REXTON SM - 2004.4 AFFECTED VIN...
Page 752 8D-9 INSPECTION CHECKING THE BRAKING FORCE Inspect the parking brake as following; 1. Count the number of the clicks (notches) when pulling up the parking brake with 19 kg of force. Specified Notch 2. If the clicks are over or below the specified value, adjust the clicks to the specified value with the parking brake adjusting nut.
Page 753 8D-10 TROUBLE DIAGNOSIS Symptom Cause Action Poor Braking Lining wear, hardening Replace Oil or water contamination on the lining Replace or repair Brake cable sticked or damage Replace Excessive pedal travel Notch adjustment Inoperative clearance automatic control system Repair PARKING BRAKE CHANGED BY EFFECTIVE DATE REXTON SM - 2004.4...
Page 754 8E1-1 SECTION 8E1 Table of Contents GENERAL ..............8E1-3 Summary ..............8E1-3 Driving physics ............8E1-3 EBD (Electronic Brake Force Distribution) system . 8E1-6 REPAIR INSTRUCTIONS ..........8E1-7 On-vehicle service ........... 8E1-7 Input and output diagram of ABS unit ...... 8E1-9 ELECTRIC CIRCUIT DIAGRAM .........
Page 755 8E1-3 GENERAL SUMMARY The aim of the ABS is to mmaintain steerability and driving stability and to take the burden off the driver. If the stopping distance is shorter on some road surfaces (carriageway conditions), this is a gift of physics and not a development aim. ABS is a device which senses that one or more of the wheels are locking up during braking.
Page 756 8E1-4 Slip The brake slip is the difference between the vehicle speed and the wheel circumference speed. If the wheel locks, the slip is greatest, that is 100 %. If the wheel is running freely and unbraked, the slip is the lowest, equal to 0 %. Slip can be calculated from the vehicle speed Vveh and the wheel speed V .
Page 757 8E1-5 Brake and cornering force - Brake force ABS-Control range When depressing the brake pedal the brake force increases to the maximum, then the brake force decreases until the Stable Unstable wheel locks. - Cornering force Brake force The cornering force is a maximum when the wheel is turning freely with zero slip.
Page 758 8E1-6 EBD (ELECTRONIC BRAKE FORCE DISTRIBUTION) SYSTEM System Description As an add-on logic to the ABS base algorithm, EBD works in a range in which the intervention thresholds for ABS control can not be reached. EBD ensures that the rear wheels are sensitively moni- tored for slip with respect to the front axle.
Page 759 8E1-7 REPAIR INSTRUCTIONS ON-VEHICLE SERVICE Service Precautions Electronic system service precautions Take care to avoid electronic brake control module (HECU) Notice circuit overloading. In testing for opens or shorts, do not ground or apply voltage to any circuit unless instructed to Brake Fluid may irritate eyes and skin.
Page 760 8E1-8 System Layout Newly introduced ABS has a different shape of integrated hydraulic modulator and HECU (Hydraulic and Electronic Control Unit) compared to existing ABS. And, the wheel speed sensor uses different method to detect wheel speed. The basic function of the ABS that maintains the vehicle stability by controlling the steerability of the vehicle when braking has not been changed.
Page 761 8E1-9 INPUT AND OUTPUT DIAGRAM OF ABS UNIT Battery + (hydraulic valve CAN LO and ECU power supply) CAN HI Battery + (pump supply power) ABS warning lamp (instrument panel) Brake switch Diagnosis connector pin no.8 Wheel speed sensor (FL) Wheel speed sensor (FR) Ground (pump) Wheel speed sensor (RL)
Page 762 8E1-10 ELECTRIC CIRCUIT DIAGRAM Wheel Speed Sensor, Stop Lamp Switch, Diagnostic Connector, Warning Lamp (ABS/ESP) Y220_8E1009 CHANGED BY EFFECTIVE DATE REXTON SM - 2004.4 AFFECTED VIN...
Page 763 8E1-11 HYDRAULIC CIRCUIT DIAGRAM ABS HYDRAULIC CIRCUIT DIAGRAM Master cylinder Primary Secondary circuit circuit Damping chamber Pump Low pressure Low pressure accumulator accumulator Inlet Inlet Inlet valve valve valve (all rear (FR) (FL) wheel) Outlet valve Outlet valve Outlet valve (FR) (FL) (all rear wheel)
Page 764 8E1-12 ABS HYDRAULIC CIRCUIT PER ABS OPERATION RANGE Hydraulic Pressure Circuit when ABS is Not Operating Low pressure chamber Pump Inlet valve Outlet valve Y220_8E1013 The hydraulic pressure in the master cylinder increases through the vacuum booster and it is delivered to the wheel via the normal open inlet valve.
Page 765 8E1-13 Pressure Decreases in the Circuit when ABS is Operating Low pressure chamber Pump Inlet valve Outlet valve Pressure decreases Y220_8E1025 Even when the hydraulic pressure on each circuit is stable, the wheel can be locked as the wheel speed decreases. This is when the ABS ECU detects the wheel speed and the vehicle speed and gives the optimized braking without locking the wheels.
Page 766 8E1-14 COMPONENTS LOCATION When Installed In Vehicle Front RH wheel Primary master cylinder Front LH wheel Secondary master cylinder ESP only (Rear RH wheel) Rear RH/LH wheel (ESP: Rear LH wheel) Wheel speed sensor Wheel speed sensor Front wheel speed sensor Rear wheel speed sensor Y220_8E1017 CHANGED BY...
Page 767 8E1-15 HECU (HYDRAULIC & ELECTRONIC CONTROL UNIT) HECU consists of motor pump (1), solenoid valve (2) and ECU (3). ECU connector has 47 pins and the number of valves in valve body is 6 when equipped with only ABS and 12 when equipped with ESP system.
Page 768 8E1-16 (Pumping) When the cam pushes the left plunger during motor operation, the system pressure is generated in the left cylinder. At this time, the right plunger is expanded by spring force and the expanded volume of the right cylinder draws the brake fluid. Y220_8E1021 ECU (Including Solenoid Valves –...
Page 769 8E1-17 WHEEL SPEED SENSOR Active Wheel Sensor - Measuring bridge with four resisters - Measuring the current - Supplying the voltage (12 V) - Amplifier/comparison measuring device Y220_8E1024 Function of Active Wheel Sensor The speed sensor used in traditional ABS is made of perma- nent magnet and transmits the output voltage that changes as the wheel rotor rotates to the HECU system.
Page 770 8E1-18 COMPONENTS LOCATOR Y220_8E1027 1. ABS hydraulic device and control unit 4. Diagnostic connector 2. Rear wheel speed sensor 5. Front wheel speed sensor 3. ABS warning lamp CHANGED BY EFFECTIVE DATE REXTON SM - 2004.4 AFFECTED VIN...
Page 771 8E1-19 REMOVAL AND INSTALLATION HYDRAULIC DEVICE/HECU ASSEMBLY Removal and Installation 1. Disconnect the negative cable. 2. Disconnect the ABS wiring harness connector from HECU socket. 3. Cover the connector and the socket with shop cloths to protect them from brake fluid. Y220_8E1028 Notice Take care not to allow air into the hydraulic...
Page 772 8E1-20 FRONT WHEEL SPEED SENSOR Removal and Installation 1. Disconnect the negative battery cable. 2. Disconnect the front wheel speed sensor connector. Y220_8E1062 3. Raise and suitably support the vehicle. 4. Turn the steering wheel to expose the front wheel speed sensor.
Page 773 8E1-21 SYSTEM FUSE The ABS/TCS system fuse and SB2 is located at the fuse box in engine compartment. Y220_8E1035 INDICATORS The ABS and TCS indicators are in instrument cluster. Y220_8E1036 CHANGED BY REXTON SM - 2004.4 EFFECTIVE DATE AFFECTED VIN...
Page 774 8E1-22 ABS FRONT TOOTH WHEEL Removal 1. Remove the disc brake rotor. Refer to Front Disc Brakes Section. 2. Remove the ABS front tooth wheel using the ABS tooth wheel puller (1). Y220_8E1068 Installation 1. Install the ABS front tooth wheel using the ABS tooth wheel installer (2).
Page 775 8E1-23 SPECIAL TOOLS AND EQUIPMENT Name and Part Number Application 661 589 16 33 00 ABS tooth wheel puller Y220_8E1071 Y220_8E1070 661 589 17 33 00 ABS tooth wheel installer Y220_8E1072 Y220_8E1073 CHANGED BY REXTON SM - 2004.4 EFFECTIVE DATE AFFECTED VIN...
Page 776 MEMO ..................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................
Page 777 8E2-1 SECTION 8E2 ESP SYSTEM Table of Contents GENERAL ..........8E2-3 FUNCTION DESCRIPTION AND REMOVAL/ INSTALLATION ........8E2-22 Summary .......... 8E2-3 Steering Wheel Angle Sensor (SWAS) COMPONENTS ........8E2-4 ............8E2-22 Components location ....... 8E2-4 Sensor cluster ........ 8E2-26 Comparison for specifications ..8E2-5 Removal and Installation ....
Page 778 8E2-3 GENERAL SUMMARY ESP (Electronic Stability Program) recognizes critical driving conditions, such as panic reactions in dangerous situations, and stabilizes the vehicle by wheel-individual braking and engine control intervention with no need for actuating the brake. This system is developed to help the driver avoid the danger of losing the control of the vehicle stability due to under-steering or over-steering during cornering.
Page 779 8E2-4 COMPONENTS COMPONENTS LOCATION 1. HECU 2. Pressure sensor 3. Wheel speed sensor 4. Sensor cluster 5. Steering wheel angle sensor 6. ESP OFF switch Y220_8E2002 Name Location HECU In front of RH dash panel in engine compartment Pressure sensor Under master cylinder (two) Wheel speed sensor Active wheel speed sensor (four)
Page 780 8E2-5 COMPARISON FOR SPECIFICATIONS Specifications Name Reference CPU: MCU60 (32 bit) CPU: MCU60 (32 bit) Clock Frequency: 28 MHz Clock Frequency: 33 MHz HECU Memory: 128 ~ 256 KB Memory: 256 ~ 512 KB Switched Orifice Switched Orifice Wheel speed sensor Active Type Active Type Output: 7 ~ 14 mA...
Page 781 8E2-6 INPUT AND OUTPUT DIAGRAM OF ESP UNIT Batt. + (voltage to hydraulic v/v) CAN LO Battery + (voltage to pump) CAN HI Brake switch ESP switch Wheel speed sensor (FL) I/P (ABS warning lamp) Wheel speed sensor (FR) Wheel speed sensor (RL) Diagnosis connector Wheel speed sensor...
Page 782 8E2-7 ESP CONTROL The ESP system includes the ABS/EBD and ASR systems allowing the system to be able to operate depending to the vehicle driving conditions. For example, when the brakes are applied during cornering at the speed of 100 km/h, the ABS system will operate at the same time the ASR or ABD systems operate to reduce the power from the slipping wheel.
Page 783 8E2-8 Oversteering Desired course Without Braked wheel Compen- sating yaw moment Braking force Y220_8E2004 Oversteering Oversteering is when the steering wheel is steered to a certain angle during driving and the rear tires slip outward losing traction. When compared with under steering vehicles, the controlling of the vehicle is difficult during cornering and the vehicle can spin due to rear wheel moment when the rear tires lose traction and the vehicle speed increases.
Page 784 8E2-9 Vehicle Control During Cornering The figure below shows the vehicle controls by ESP system under various situations such as when the brake pedal is pressed (or not pressed) during cornering and when the ABS is operating or when just the conventional brake is operat- ing during braking.
Page 785 8E2-10 Hydraulic Diagram of ESP Pressure sensor Damper Damper (primary circuit) (secondary circuit) Separation Separation valve valve (NO) (NO) Damping chamber Shuttle Shuttle valve Pump valve Low pressure accumulator FL inlet inlet valve valve inlet valve inlet valve (NO) (NO) (NO) (NO) outlet...
Page 786 8E2-11 When equipped with ABS, the braking force at each wheel will be controlled with 3-channel 4-sensor method. And when equipped with ESP, 4 wheels will be controlled independently with 4-channel method. (When controlling ABS system only, it will be operated with 3-channel method.) When compared to the vehicle equipped with ABS/EBD only, the internal hydraulic circuit has a normally-open separation valve and a shuttle valve in primary circuit and in secondary circuit.
Page 787 8E2-12 (1) ESP Hydraulic unit in idling and normal braking position Low pressure chamber Shuttle valve Separation valve Pump Outlet valve Inlet valve Y220_8E2014 In this position, the separation valve and the inlet valve are open (normal open), the electrically operated shuttle valve and the outlet valve are closed.
Page 788 8E2-13 (2) When applied ABS (decreased pressure) Low pressure chamber Shuttle valve Separation valve Pump Inlet valve Outlet valve Y220_8E2015 The pressure decreases just before the wheel speed drops and the wheels. The inlet valve closes and the outlet valve opens as in the ABS HECU and the oil is gathered at the low pressure chamber while no additional oil is being supplied.
Page 789 8E2-14 (3) When applied ABS (maintained pressure) Low pressure chamber Shuttle valve Separation valve Pump Outlet valve Inlet valve Y220_8E2016 The Inlet valve and outlet valve will be closed to maintain the pressure in the hydraulic circuit applied at the wheels. By closing the valves, the hydraulic pressure at the wheels will not be lost or supplied any more.
Page 790 8E2-15 (4) When applied ABS (increased pressure) Low pressure chamber Shuttle valve Separation valve Pump Outlet valve Inlet valve Y220_8E2017 The shuttle valve and inlet valve will be open and the separation valve and outlet valve will be closed. Then, the pump is operated.
Page 791 8E2-16 HBA (Hydraulic Brake Assist System) Experienced drivers Inexperienced drivers Elderly and physically weak drivers Time (s) Y220_8E2018 (1) Purpose HBA (Hydraulic Brake Assist) system helps in an emergency braking situation when the driver applies the brake fast, but not with sufficient pressure, which leads to dangerously long braking distance.
Page 792 8E2-17 (3) Hydraulic Diagram of HBA Low pressure chamber Shuttle valve Outlet valve Separation valve Inlet valve Pump Rear wheel Outlet valve Inlet valve Front wheel Y220_8E2020 The above figure shows one front and one rear wheel and the same hydraulic circuit forms as in the ESP operation. When HECU recognizes that it is an emergency and it is required for hard braking, depending on the pressure value of the brake pressure sensor and pressure changes caused by the pressure sensor timing, it operates the pump immedi- ately to apply the brake pressure at the wheels.
Page 793 8E2-18 ESP COMPONENTS HECU (HYDRAULIC AND ELECTRONIC CONTROL UNIT) ECU (Electronic Control Unit) The electronic control unit performs the following functions: - controlling the ABS and ESP - cotinuous monitoring of all electrical components In the integrated control unit, the coils of the solenoid valves are integrated into the control unit housing.
Page 794 8E2-19 (1) When installed in vehicle Front wheel RH Primary master cylinder Front wheel LH Only for ESP Secondary master cylinder (Rear wheel RH) Rear wheel RH/LH (for ESP, rear wheel LH) Y220_8E2024 HECU consists of motor pump, solenoid valve and ECU. ECU connector has 47 pins and the number of valves in valve body is 12 when equipped with ABS/ESP, and they cannot be disassembled.
Page 795 8E2-20 Connector Y220_8E2026 Pin no. Name Current Tange Voltage Range ABS ECU Battery (B+) Max. 30 A 0 ~ 18 V Self diagnosis (K-Line) Max.100 mA 0 ~ 18 V Steering wheel angle sensor (STN) Max. 10 mA 0 ~18 V IGN1 Max.
Page 796 8E2-21 WHEEL SPEED SENSOR Active Wheel Sensor - Measuring bridge with four resisters - Measuring the current - Supplying the voltage (12 V) - Amplifier/comparison measuring device Function of Active Sensor System The basic tone wheel and the magnetized encoder wheel to activate the sensor.
Page 797 8E2-22 FUNCTION DESCRIPTION AND REMOVAL/INSTALLATION STEERING WHEEL ANGLE SENSOR (SWAS) The steering wheel angle sensor is located between clock spring and multifunction switch. This sensor is used for recognition of driver’s intends. If the sensor is replaced with new one, it can detect the neutral position after the vehicle is moving over 20 km/h for more than 5 seconds.
Page 798 8E2-23 Steering wheel angle sensor connector Phototransistor Steering column Slotted plate Steering wheel angle Y220_7A2030 The steering wheel angle sensor is integrated with the phototransistor and the LED and there is a slotted plate between them. When the inner slotted plate rotates with the steering column shaft when the steering wheel is turned, the voltage occurs through the holes.
Page 799 8E2-24 Removal and Installation 1. Disconnect the negative battery cable. 2. Place the steering wheel and tires to straight ahead direction. 3. Unscrew the mounting screws on driver’s side dash panel and remove the lower blinder outer panel and cover. Y220_7A2033 4.
Page 800 8E2-25 7. Mark on steering wheel mounting nut and remove the steering wheel. Y220_7A2037 8. Unscrew the upper and lower mounting screws and remove the steering column cover. Y220_7A2038 9. Remove the air bag sensor module from the steering wheel. Y220_7A2039 10.
Page 801 8E2-26 SENSOR CLUSTER The lateral acceleration sensor and the yaw rate sensor are important components of the Electronic Stability Program. The cluster links these sensors to an on-board computer unit and to a CAN interface, incased in a sturdy housing, that is mounted on the chassis.
Page 802 8E2-27 (3) Sensor cluster circuit Power Ground Power Sensor cluster ESP unit Y220_8E2043 (4) Specification (sensor cluster: yaw rate sensor + lateral acceleration sensor + Longitudinal acceleration sensor) Descriptions Specifications Supplying voltage Approx. 5 V (4.75 ~ 5.25 V) Output voltage when stop Approx.
Page 803 8E2-28 (6) Lateral/Longitudinal acceleration sensor These sensors sense the lateral/longitudinal acceleration of the vehicle and located in sensor cluster. For 4WD vehicle, the longitudinal sensor is located in sensor cluster and the functions are same only except the direction. The lateral ac- celeration sensor detects the movement of lateral direction and the longitudinal acceleration sensor detects the movement of longitudinal direction (driving direction).
Page 804 8E2-29 REMOVAL AND INSTALLATION 1. Remove the sensor cluster mounting bolts. Y220_8E2048 2. Disconnect the sensor cluster connector. Y220_8E2049 3. Remove the sensor cluster unit. Y220_8E2050 4. Install in the reverse order of removal. ESP SYSTEM CHANGED BY REXTON SM - 2004.4 EFFECTIVE DATE AFFECTED VIN...
Page 805 8E2-30 PRESSURE SENSOR (1) Location Y220_8E2038 1. Master cylinder 4. Inside of pressure sensor 2. Primary pressure sensor 5. Connector 3. Second pressure sensor (2) Pressure sensor circuit Ground • HBA operating conditions with output value from Power pressure sensor: - pressure: 20 bar Signal output - pressure deviation: over 1500 bar/sec...
Page 806 8E2-31 (4) Pressure sensor a. The pressure sensor senses the driver’s braking intentions (braking while an ESP intervention is in progress) and controls the precharging pressure. Y220_8E2040 b. The sensor consists of two ceramic disks, one of which is stationary and the other movable. The distance between these disks changes when pressure is applied.
Page 807 8E2-32 If two signals from pressure sensor deviates from the specified value, HECU determines the sensor is faulty. The sensor output is analog signal that is proportional to voltage and the HECU recognized the pressure value as signal value against supplying voltage. Maximum measurable pressure: 170 bar Linear changes of about 0.5 volts when the brake is not operating and 4.75 volts when the brake is operating.
Page 808 8E2-33 ESP OFF SWITCH ESP OFF switch is located at center switch panel. When pressing the switch, the ESP warning lamp lights up and ESP and TCS function is deactivated. However, the ABS function is still activated. Y220_8E2057 Automatic coding When replacing the HECU with new one, it is coded automatically.
Page 809 8E2-34 WARNING LAMP AND INDICATOR (1) ESP warning lamp blinking in control ESP warning lamp blinks when ESP control is activated. If the activation reaches a certain limitation, a beep sounds to warn the driver. The ESP warning lamp goes off when ESP function is deactivated. Even when the ESP is operated for a very short period of time, the ESP warning lamp blinks minimum of 4 times every 175 milliseconds and the buzzer sounds for at least 1.4 seconds with 100 ms interval.
Page 810 8E2-35 (3) Resuming the ESP system by using the ESP OFF switch The ESP system will be resumed and the ESP warning lamp at the instrument panel goes off when the ESP switch at the center switch panel is pushed (for over approximately 150 ms) while the ESP system is not operating. The detailed operation procedures are as follows.
Page 811 8E2-36 (4) ESP OFF switch monitoring When the ESP unit recognizes that the ESP OFF switch is pushed for over 60 seconds, the ESP unit determines it as a ESP OFF switch malfunction. When the ESP OFF switch is pushed, the ESP system is resumed after 60 seconds. However, the ESP warning lamp comes on when the ESP OFF switch is pushed (for over 150 ms) and then goes out when the ESP system is resumed.
Page 812 8E2-37 AIR BLEEDING FROM BRAKE SYSTEM The vehicle equipped only with ABS can use the conventional air bleeding procedures, however, the vehicle equipped with ESP should use the oil supply device with compressor to bleed the air. Air bleeding should be done when: 1.
Page 813 8E2-38 TROUBLE DIAGNOSIS [O: Applied, X: N/A] Trouble Defective Components Descriptions Code Cause - Defective front LH wheel speed sensor - Short or poor contact wire to sensor C1011 Wheel speed sensor Action (5011) front left-electrical - Check the wheel speed sensor connector and HECU connector - Check the harness connection Cause...
Page 814 8E2-39 Trouble Defective Components Descriptions Code Cause - Defective rear RH wheel speed sensor - No signals from wheel speed sensor and tooth wheel - Too large air gap between wheel speed sensor and C1032 Wheel speed sensor rear tooth wheel (5032) right-other - Different number of teeth in tooth wheel...
Page 815 8E2-40 Trouble Defective Components Descriptions Code C1071 Longitudinal acceleration (5071) sensor C1072 Longitudinal acceleration (5072) sensor Cause - Operating voltage exceeds specified range (Hi: 18.0 ± 1.0 V / Lo: 6.5 ± 0.5 V) C1073 Sensor cluster -electri- - Poor contact or installation of harness (5073) Action - Check the sensor cluster connector...
Page 816 8E2-41 Trouble Defective Components Descriptions Code Cause - Mechanical defective in brake switch C1201 Brake lamp switch - Defective brake switch harness (5201) Action - Check the harness and connector Cause - Mechanical defective in ESP OFF switch C1202 - Defective ESP OFF switch harness (short to ground) ESP OFF switch (5202) Action...
Page 817 8E2-42 Trouble Defective Components Descriptions Code Cause - Coding error - Defective CAN communication line C1170 Variant coding error ( O ) - Discrepancy between HECU coding and vehicle coding (5170) Action - Check the HECU coding and vehicle coding - Replace the HECU Cause - Defective CAN communication line...
Page 818 8E2-43 ABS/ESP SENSOR VALUE Contnet Unit Wheel Speed Front RH 1 km/h Wheel Speed Front LH 1 km/h Wheel Speed Rear RH 1 km/h Wheel Speed Rear LH 1 km/h Battery Voltage 0.1 V Longitudinal Acceleration Sensor 0.01 g - : Straight ahead (Fixed Value: 0) Lateral Aceleration Sensor 0.01 g...
Page 819 8E2-44 ABS/ESP FORCED OPERATION Operation Name Front LH Inlet Operation / Non-operation Operation / Non-operation Front LH Outlet Valve Front RH Inlet Operation / Non-operation Operation / Non-operation Front RH Outlet Valve Rear (or RL) Inlet Valve (x1) Operation / Non-operation Operation / Non-operation Rear (or RL) Outlet Valve (x1) (Rear RH Inlet Valve (x2))
Page 820 8E2-45 INITIALIZATION INTIALIZE SENSOR(Only ESP) INTIALIZE SENSOR 1] LONGITUDINAL ACCEL SENSOR(4WD only) 2] LATERAL ACCEL SENSOR 3] PRESSURE SENSOR 4] ABOVE 1, 2, 3 ALL SENSOR Select one of the above items INTIALIZE SENSOR LONGITUAINAL ACCEL SENSOR(4WD only) DO YOU START INITIALIZE ? (Yes/No) CONDITION : - ENGINE IS NOT RUNNING.
Page 821 8E2-46 ACTUATOR ACTUATOR TEST ACTUATOR TEST 1] FRONT/LEFT INLET VALVE 2] FRONT/LEFT OUTLET VALVE 3] FRONT/RIGHT INLET VALVE 4] FRONT/RIGHT OUTLET VALVE 5] REAR(ESP: REAR/LEFT) INLET VALVE 6] REAR(ESP: REAR/LEFT) OUTLET VALVE 7] REAR/RIGHT(Only ESP) INLET VALVE 8] REAR/RIGHT(Only ESP) OUTLET VALVE 9] 1st TCS VALVE(Only ESP) 10] 2nd TCS VALVE(Only ESP) 11] 1st ESV VALVE(Only ESP)
Page 822 8E2-47 AIR BLEEDING AIR BLEEDING(TEVES ABS/ESP) 1] REAR/RIGHT CHANNEL 2] REAR/LEFT CHANNEL 3] FRONT/LEFT CHANNEL 4] FRONT/RIGHT CHANNEL Select one of the above items AIR BLEEDING(TEVES ABS/ESP) > > > > REAR/RIGHT AIR BLEEDING < < < < 1] OPEN THE BLEED SCREW. 2] CONTINUALLY PUMPING BRAKE PEDAL.
Page 823 8E2-48 CODE CLEAR CLEAR VARIANT CODE REXTON ABS ABS/ESP(TEVES) DO YOU START CLEAR ? (YES / NO) ESP SYSTEM CHANGED BY EFFECTIVE DATE REXTON SM - 2004.4 AFFECTED VIN...
Page 824 8E2-49 ELECTRIC CIRCUIT DIAGRAM ABS/ESP Wheel Speed Sensor, Stop Lamp Switch, Diagnostic Connector, Warning Lamp (ABS/ESP) Y220_8E2061 ESP SYSTEM CHANGED BY REXTON SM - 2004.4 EFFECTIVE DATE AFFECTED VIN...
Page 825 8E2-50 Brake Pressure Sensor, Steering Wheel Angle Sensor, Sensor Cluster, ESP OFF Switch Y220_8E2062 ESP SYSTEM CHANGED BY EFFECTIVE DATE REXTON SM - 2004.4 AFFECTED VIN...
Page 826 SECTION ELECTRIC SYSTEM CONTENTS GENERAL ..............9A ELECTRIC SYSTEM............9B INSTRUMENT PANEL AND MULTI-METER ....9C SWITCHES..............9D LAMPS ................9G WIPER & WIPER MOTOR/HORN ......... 9H...
Page 827 9A-1 SECTION 9A GENERAL Table of Contents GENERAL INFORMATION ..........9A-3 INSPECTION OF CABLES AND WIRES ......9A-5 FUSES AND RELAYS ............. 9A-6 DI (D27DT) engine equipped vehicle ......9A-6 IDI (D29ST) engine equipped vehicle ....... 9A-9 Gasoline engine equipped vehicle ......9A-12 ELECTRIC COMPONENTS LOCATOR ......
Page 828 9A-3 GENERAL INFORMATION 1. Before starting repairs which do not require battery power: Turn off ignition switch. Disconnect the negative battery cable. Notice • Turn off all the electrical devices before disconnecting and connecting the negative battery cable. Otherwise, the semiconductor components are subject to be damaged.
Page 829 9A-4 7. Loosened connection may cause a malfunction. Always firmly engage the connector. 8. When connecting, push the connector until it sounds “click”. 9. When disconnecting, always hold the connector body other than the harness. Y220_09A004 10. Disconnect the connector while pressing down the locking tab if applicable.
Page 830 9A-5 INSPECTION OF CABLES AND WIRES 1. Check the connections for looseness and rust. 2. Check the terminals and wires for corrosion due to electrolyte. 3. Check the circuit for open. 4. Check the wire insulation. Check the cover clothing of the wire for damage, crack and deterioration. 5.
Page 831 9A-6 FUSES AND RELAYS DI (D27DT) ENGINE EQUIPPED VEHICLE Fuse Box In Engine Compartment It is installed in the left side of engine compartment. Name and Capacity Connector Arrangement Y220_09A007 GENERAL CHANGED BY EFFECTIVE DATE REXTON SM - 2004.4 AFFECTED VIN...
Page 832 9A-7 Interior Fuse Box It is install at left side of the instrument panel. Name and Capacity Y220_09A010 GENERAL CHANGED BY REXTON SM - 2004.4 EFFECTIVE DATE AFFECTED VIN...
Page 833 9A-8 Interior Relay Box It is installed behind the lower instrument panel. Relay Arrangement Relay Name Y220_09A013 GENERAL CHANGED BY EFFECTIVE DATE REXTON SM - 2004.4 AFFECTED VIN...
Page 834 9A-9 IDI (D29ST) ENGINE EQUIPPED VEHICLE Fuse Box In Engine Compartment It is installed in the left side of engine compartment. Fuse Name and Capacity Connector Arrangement Y220_09A016 GENERAL CHANGED BY REXTON SM - 2004.4 EFFECTIVE DATE AFFECTED VIN...
Page 835 9A-10 Interior Fuse Box It is install at left side of the instrument panel. Name and Capacity Y220_09A019 GENERAL CHANGED BY EFFECTIVE DATE REXTON SM - 2004.4 AFFECTED VIN...
Page 836 9A-11 Interior Relay Box It is installed behind the lower instrument panel. Relay Arrangement Relay Name Y220_09A023 GENERAL CHANGED BY REXTON SM - 2004.4 EFFECTIVE DATE AFFECTED VIN...
Page 837 9A-12 GASOLINE ENGINE EQUIPPED VEHICLE Fuse Box In Engine Compartment It is installed in the left side of engine compartment. Fuse Name and Capacity Connector Arrangement Y220_09A024 GENERAL CHANGED BY EFFECTIVE DATE REXTON SM - 2004.4 AFFECTED VIN...
Page 838 9A-13 Interior Fuse Box It is install at keft side of the instrument panel. Name and Capacity Fuse Y220_09A027 GENERAL CHANGED BY REXTON SM - 2004.4 EFFECTIVE DATE AFFECTED VIN...
Page 839 9A-14 Interior Relay Box It is installed behind the lower instrument panel. Relay Name Relay Arrangement Y220_09A031 GENERAL CHANGED BY EFFECTIVE DATE REXTON SM - 2004.4 AFFECTED VIN...
Page 840 9A-15 ELECTRIC COMPONENTS LOCATOR Y220_09A032 GENERAL CHANGED BY REXTON SM - 2004.4 EFFECTIVE DATE AFFECTED VIN...
Page 841 MEMO ..................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................
Page 842 9B-1 SECTION 9B ELECTRIC SYSTEM Table of Contents IGNITION KEY AND REMOTE CONTROL KEY .... 9B-3 Remote Keyless Entry System (REKES) ....9B-3 REKES + STICS (RKSTICS) .......... 9B-5 Components locator ..........9B-5 Specifications ............. 9B-6 Rated load ..............9B-6 Chattering of input signals .........
Page 843 9B-3 IGNITION KEY AND REMOTE CONTROL KEY REMOTE KEYLESS ENTRY SYSTEM (REKES) 1. UNLOCK button (1): Unlocks all doors. 2. LOCK button(2): Locks all doors. Y220_09B034 Battery Replacement Use a CR 2025 battery for replacement. Y220_09B047 ELECTRIC SYSTEM CHANGED BY REXTON SM - 2004.4 EFFECTIVE DATE AFFECTED VIN...
Page 844 9B-4 Immobilizer System The Immobilizer System provides an additional theft deterrent to the vehicle in which it is installed and prevents it from being started by unauthorized persons. When the ignition key with integrated transponder is turned to the ON position, ECU (Engine Control Unit) checks the crypto code of key and, if correct, allow the vehicle to start the engine.
Page 845 9B-5 REKES + STICS (RKSTICS) COMPONENTS LOCATOR Y220_09B053 1. RK-STICS 3. Buzzer 2. Interior fuse box 4. Outside mirror folding unit ELECTRIC SYSTEM CHANGED BY REXTON SM - 2004.4 EFFECTIVE DATE AFFECTED VIN...
Page 846 9B-6 SPECIFICATIONS Description Specification Remark Rated voltage DC 12 V Operating voltage DC 9 ~ 16 V Operating temperature -30°C ~ +80°C Reserved temperature -40°C ~ +85°C Max. operating humidity 95 % Resistible voltage 24 V Insulating resistance No heat and fire due to the Confined with PCB, waterproof and coating that require the insulation current leaks...
Page 847 9B-7 CHATTERING OF INPUT SIGNALS 1. Vehicle speed input The vehicle speed calculating time is 1.0 second. The elapsed time of 1.5 seconds after IGN1 switch “ON” is not included. 2. 150 ms target input Door lock switches, tailgate lock switch 3.
Page 848 9B-8 WIPER CONTROL Wiper MIST and Washer Coupled Wiper 1. The wiper MIST and washer coupled wiper output is “ON” when turning “ON” the washer switch for 0.2 ~ 0.59 seconds. Y220_09B054 2. The wiper MIST and washer coupled wiper output is “ON” when turning “ON” the washer switch for over 0.6 seconds. T1 : Over 0.6 sec T2 : 0.3 ±...
Page 849 9B-9 3. If turning “ON” the washer switch for over 0.6 seconds while the intermittent wiper is operating, the wiper relay turns “ON” from T2 after the washer switch is turned “ON” and it is turns “OFF” from 3 cycles after the washer switch is turned “OFF”.
Page 850 9B-10 Speed Sensitive INT (intermittent) Wiper 1. Controls the wiper intermittent operation by the values from vehicle speed and volume - Calculates and converts the intermittent time automatically by using the vehicle speed and INT VOLUME when IGN 2 switch is “ON” and INT switch is “ON”. 2.
Page 851 9B-11 Pause time table of vehicle speed coupled INT wiper Resistance Pause time (sec) Vehicle speed Y220_09B057 ELECTRIC SYSTEM CHANGED BY REXTON SM - 2004.4 EFFECTIVE DATE AFFECTED VIN...
Page 852 9B-12 IGNITION KEY REMINDER The ignition key reminder warning has priority over the “MARKER LAMP LEFT ON WARNING”. Chime Bell Control 1. The chime bell output is “ON” when opening the driver’s door while the ignition key is inserted into ignition switch. 2.
Page 853 9B-13 Door Control 1. The door unlock relays output is “ON” when the driver’s door lock switch turns “ON” while the ignition key is inserted into ignition switch and the driver’s door opens. 2. The door unlock relays output is “ON” when the passenger’s door lock switch turns “ON” while the ignition key is inserted into ignition switch and the passenger’s door opens.
Page 854 9B-14 MARK LAMP LEFT ON WARNING Buzzer Control 1. The buzzer output is “ON” when opening the driver’s door or passenger’s door while the tail lamp relay turns “ON” and the ignition key is removed.. 2. The buzzer output is “OFF” when any of above conditions are not met. 3.
Page 855 9B-15 Door Control 1. The door unlock relay output is “ON” when opening the driver door or passenger’s door and locking the door lock switch while the tail lamp relay output is “ON” and the ignition key is removed. 2. The door unlock relay output is “OFF” when closing both doors or turning off the tail lamp switch. 3.
Page 856 9B-16 DOOR AJAR WARNING 1. The warning lamp comes on when opening a door while the vehicle speed is below 3 km/h. 2. The warning lamp blinks when opening a door while the vehicle speed is over V1 (10 km/h). 3.
Page 857 9B-17 SEATBELT WARNING TIMER 1. The seatbelt warning lamp comes on and the chime bell sounds for 6 seconds when turning “ON” the IGN 1 switch. 2. The seatbelt warning lamp goes off and the chime bell stops when turning “OFF” the IGN 1 switch during the warning operation.
Page 858 9B-18 PARKING BRAKE WARNING 1. The parking brake warning lamp comes on for approx. 4 seconds when turning “ON” the IGN 1 switch regardless of the vehicle speed and parking brake switch position. After this 4 seconds, the warning lamp comes on, goes off and blinks according to the vehicle speed and parking brake switch position.
Page 859 9B-19 DECAYED ROOM LAMP TIMER 1. The room lamp comes on when opening the door while the room lamp switch is at coupled operating position, IGN 1 switch output is “OFF” and the driver’s and passenger’s door switch are at unlock position. 2.
Page 860 9B-20 IGNITION KEY HOLE ILLUMINATION 1. The ignition key hole illumination comes on when opening the door while the ignition key is removed. 2. The ignition key hole illumination stays on 10 seconds after closing the door in step 1. 3.
Page 861 9B-21 REAR DEFOGGER TIMER 1. The rear defogger output is “ON” when turning “ON” the rear defogger switch while the IGN 2 switch is “ON” (with engine running). 2. The output is “OFF” when turning “ON” the rear defogger switch again during outputting. 3.
Page 862 9B-22 DOOR LOCK/UNLOCK CONTROL Door Lock/Unlock by Door Lock Switch 1. The door lock output is “LOCK” for T1 when positioning the driver’s or passenger’s door lock switch to lock position. 2. The door lock output is “UNLOCK” for T2 when positioning the driver’s or passenger’s door lock switch to unlock position.
Page 863 9B-23 Lock/Unlock by REKES (Remote Keyless Entry System) 1. The door lock relay output is “ON” for 0.5 seconds when receiving the remote control lock signal. 2. The door unlock relay output is “ON” for 0.5 seconds when receiving the remote control unlock signal. REMOTE CONTROL SIGNAL SIGNAL...
Page 864 9B-24 Auto Door Lock 1. All door lock relay outputs are “ON” when the vehicle speed keeps over V1 while the IGN 1 switch turns “ON”. However, if all doors are locked or failed, the output will not be “ON”. 2.
Page 865 9B-25 Auto Door Unlock (Unlocking When Taking An Impact) 1. The auto door unlock relay turns “ON” automatically when taking an impact while the IGN 1 switch turns “ON” and the vehicle speed is over 15 km/h. 2. If taking an impact again after manually locking in above “UNLOCK” condition (IGN “ON”), “UNLOCK” can be done regardless of the numbers of operation.
Page 866 9B-26 TIME LAG POWER WINDOW CONTROL 1. The power window relay output is “ON” when turning on the IGN 1 switch. 2. The power window relay output is “ON” for T1 when turning off the IGN 1 switch. 3. The power window relay output is “ON” for T2 when opening the door within T1. 4.
Page 867 9B-27 REKES Specifications of Transmitter 1. Transmitter signals - When pressing a switch on the transmitter, sends the data as follows. - When pressing over two switches at a time, only one signal can be sent according to the below priority. - Priority: LOCK ⇒...
Page 868 9B-28 3. Registration of receiver code - Only one receiver code can be registered. - The received code cannot be output during the registration. - The hazard relay output is “ON” for T1 and the siren output is “ON” for T2 when registering the code. •...
Page 869 9B-29 THEFT WARNING Theft Warning Selection 1. When the theft warning selection switch is “ON” - When a warning operating condition occurs, the warning outputs (Hazard relay/Siren) will not be done. However, if the armed mode is started, the hazard relay output is “ON”. - When turning “OFF”...
Page 870 9B-30 2. Armed mode cancellation requirements - Unlocking by Tx, turning “ON” the door unlock switch, inserting the ignition key into the ignition switch, turning “ON” the IGN 1 switch, turning “ON” the IGN 2 switch - Armed mode cancellation requirements for tailgate The armed ready mode for tailgate is activated when turning “ON”...
Page 871 9B-31 3. Warning operating requirements - When opening the door in armed mode - When unlocking the door lock switch in armed mode - When closing and then opening the door after completion of warning (27 seconds) 4. Warning operation - The siren output is “ON”...
Page 872 9B-32 7. Operations when removing and installing the battery Installed Normal Armed Warning Remark Removed Normal Armed Armed Ready Armed Warning Warning Completion RELOCK Ready System Power Consumption 1. The “SLEEP” mode is activated to save the system power when: - All doors (driver’s door, passenger’s door, rear doors, tailgate, hood) are closed - The IGN 1 switch and the IGN 2 switch are turned “OFF”...
Page 873 9B-33 RK-STICS Tail Lamp and Switch Y220_09B079 ELECTRIC SYSTEM CHANGED BY REXTON SM - 2004.4 EFFECTIVE DATE AFFECTED VIN...
Page 874 9B-34 Warning Lamps Y220_09B079A ELECTRIC SYSTEM CHANGED BY EFFECTIVE DATE REXTON SM - 2004.4 AFFECTED VIN...
Page 875 9B-35 Wiper, Door Switch, Lamps (Room Lamp, Map Lamp), Door Ajar Warning Lamp Y220_09B079B ELECTRIC SYSTEM CHANGED BY REXTON SM - 2004.4 EFFECTIVE DATE AFFECTED VIN...
Page 876 9B-36 Door Lock, Heated Wire Y220_09B079C ELECTRIC SYSTEM CHANGED BY EFFECTIVE DATE REXTON SM - 2004.4 AFFECTED VIN...
Page 877 9B-37 Central Door Locking Device Y220_09B079D ELECTRIC SYSTEM CHANGED BY REXTON SM - 2004.4 EFFECTIVE DATE AFFECTED VIN...
Page 878 9B-38 Removal and Installation 1. Disconnect the battery negative cable and remove the lower panel in front of driver’s seat. Y220_09B080 2. Disconnect the buzzer and folding unit connectors and remove them at a time. Y220_09B081 3. Disconnect three connectors and remove the RK-STICS unit.
Page 879 Y220_09B128 Total 5 immobilizer key can be coded to ECU with Scan-i. Refer to the coding procedures in Troubleshooting section. The immobilizer should be coded whenever replacing the immobilizer related components and ECU at the Ssangyong Authorized Service Operation. ELECTRIC SYSTEM CHANGED BY REXTON SM - 2004.4...
Page 880 9B-40 CIRCUIT DIAGRAM Y220_09B129 ELECTRIC SYSTEM CHANGED BY EFFECTIVE DATE REXTON SM - 2004.4 AFFECTED VIN...
Page 881 9B-41 COMPONENTS Transponder It receives the “ENERGY” and “CHALLENGE” signals and computes them by the crypto key in ASCI and sends the “RE- SPONSE” and serial number Condenser Coil Y220_09B130 Coil Antenna Ls (inductance): 1.08 mH It provides the “ENERGY” and “CHALLENGE” to the transponder, receives the output signals from the transponder, and delivers them to the immobilizer ECU.
Page 882 9B-42 SCHEMATIC DIAGRAM K-LINE(ANSWER) CODE Immobilizer Unit (REQUEST) CODE Transponder Coil (SERIAL NO. AND RESPONES) (ENERGY AND CHALLENGE) Y220_09B131 ELECTRIC SYSTEM CHANGED BY EFFECTIVE DATE REXTON SM - 2004.4 AFFECTED VIN...
Page 883 9C-1 SECTION 9C INSTRUMENT PANEL AND MULTI-METER Table of Contents CLUSTER ................ 9C-3 Black-face type cluster (DI/gasoline engine equipped vehicle) ...... 9C-4 BLACK-FACE TYPE CLUSTER ........9C-5 Gasoline engine equipped vehicle ......9C-5 Direct injection diesel engine equipped vehicle (with CAN communication) ......... 9C-6 Circuit diagram and connecter pin arrangement ..
Page 884 9C-3 CLUSTER Several types of clusters are used according to the vehicle models. • IDI Engine (D29ST): Conventional cluster that cannot communicate with CAN • DI Engine (D27DT): Conventional appearance + CAN communication function (internal function) New cluster with BLACK-FACE appearance (CAN communication) •...
Page 885 9C-4 BLACK-FACE TYPE CLUSTER (DI/GASOLINE ENGINE EQUIPPED VEHICLE) Y220_09C125 INSTRUMENT PANEL AND MULTI-METER CHANGED BY EFFECTIVE DATE REXTON SM - 2004.4 AFFECTED VIN...
Page 886 9C-5 BLACK-FACE TYPE CLUSTER GASOLINE ENGINE EQUIPPED VEHICLE Y220_09C230 1. Speedometer 14. WINTER mode indicator (A/T) 2. Auto shift indicator (A/T) 15. High beam indicator 3. Odometer/Trip odometer 16. Turn signal indicator (right) 4. Engine oil pressure warning light 17. Turn signal indicator (left) 5.
Page 887 9C-6 DIRECT INJECTION DIESEL ENGINE EQUIPPED VEHICLE (WITH CAN COMMUNICATION) Y220_09C231 1. Speedometer 16. Temperature gauge 2. Auto shift indicator (A/T) 17. WINTER mode indicator (A/T) 3. Odometer/Trip odometer 18. High beam indicator 4. Engine oil pressure warning lightt 19. Turn signal indicator (right) 5.
Page 888 9C-7 CIRCUIT DIAGRAM AND CONNECTER PIN ARRANGEMENT Y220_09C218 CHANGED BY INSTRUMENT PANEL AND MULTI-METER EFFECTIVE DATE REXTON SM - 2004.4 AFFECTED VIN...
Page 889 9C-8 CLEAR GLASS TYPE CLUSTER DIRECT INJECTION DIESEL ENGINE EQUIPPED VEHICLE (WITH CAN COMMUNICATION) Y220_09C232 1. Speedometer 15. High beam indicator 2. Auto shift indicator 16. Turn signal indicator (right) 3. Odometer/Trip odometert 17. Brake system warning light 4. Glow indicator 18.
Page 890 9C-9 CIRCUIT DIAGRAM AND CONNECTER PIN ARRANGEMENT DI Engine Equipped Vehicle HIGH SPEED WARNING ESP BUZZER FUEL FILTER WARNING BUZZER Water separator warning P-OUT Connector (A) Connector (B) Y220_09C233 CHANGED BY INSTRUMENT PANEL AND MULTI-METER EFFECTIVE DATE REXTON SM - 2004.4 AFFECTED VIN...
Page 891 9C-10 INDIRECT INJECTION DIESEL ENGINE EQUIPPED VEHICLE (WITHOUT CAN COMMUNICATION) Y220_09C230A 1. Speedometer 14. High beam indicator 2. Auto shift indicator 15. Turn signal indicator (right) 3. Odometer/Trip odometer 16. Brake system warning light 4. Glow indicator 17. Tachometer 5. Engine oil pressure warning light 18.
Page 892 9C-11 IDI Engine Equipped Vehicle (without CAN Communication) Connector (A) Connector (B) Connector (C) Y220_09C234 CHANGED BY INSTRUMENT PANEL AND MULTI-METER EFFECTIVE DATE REXTON SM - 2004.4 AFFECTED VIN...
Page 893 9C-12 MAINTENANCE AND REPAIR Speedometer 1. Check the allowable tolerance and operations for the speedometer and odometer by using a tester. 2. Check if the speedometer pointer is shaking and the abnormal noise sounds. 3. Eliminate the hysteresis by tapping the speedometer. Note The allowable tolerance increases when the tires are worn or the tire pressure is out of specified range.
Page 894 9C-13 Fuel Gauge 1. Disconnect the fuel sender connector. 2. Ground the harness side connector (B11, B14) through 12 V, 3.4 W lamp. 3. Turn the ignition switch to “ON” position. 4. Check it the test lamp comes on and the fuel gauge pointer moves to “F”...
Page 895 9C-14 Temperature Gauge 1. Disconnect the temperature sensor connector in engine compartment. 2. Ground the harness side connector through 12 V, 3.4 W lamp. 3. Turn the ignition switch to “ON” position. 4. Check if the test lamp comes on and the temperature gauge is moving.
Page 896 9C-15 Trip Odometer and Odometer Battery Voltage Rated voltage: DC 12 V Inspection voltage: DC 13.5 V Operating voltage range: DC 9 V ~ 16 V Operating temperature range: -30°C ~ +75°C (use same check- ing conditions with driving conditions) Battery Current Parasitic current: below 3 mA (Battery voltage 12 V at 25°C) Y220_09C223...
Page 897 9C-16 Colors and Sizes of Indicators Y220_09C229 Display Color Description Night BLACK BLACK Background Scale, Letter, Number, Mark WHITE WHITE WHITE WHITE Scale, Letter, Number Scale background SKYBLUY SKYBLUY Speedometer GCC Spec. 120 km/h Mark Tachometer Diesel: 4500 ~ 6000 Warning range Gasoline: 6500 ~ 8000 Tachometer sub-scale...
Page 898 9C-17 Oil Pressure Switch 1. Stop the engine and check the continuity between terminal and ground. 2. Start the engine and check the continuity between Ohmmeter terminal and ground. 3. Disconnect the connectors from the warning switch in wiring harness side and ground terminal. 4.
Page 899 9C-18 Parking Brake Switch The parking brake switch is installed under the parking brake lever. 1. Check the continuity between terminal and switch when turning “ON” the switch (applying the parking brake). 2. Check the continuity between terminal and switch when turning “OFF”...
Page 900 9C-19 METERS/INDICATORS/WARNING LIGHTS Speedometer Black-Face Type The speedometer indicates the vehicle speed in kilometers per hour (km/h) or mile per hour (m/h). General Type Y220_09C247 Odometer/Trip Odometer Black-Face Type When the reset button located in the right and lower area of odometer is pressed once, the first driving distance (TRIP A) will be indicated and pressed again, the second driving dis- tance (TRIP B) will be indicated.
Page 901 • If the belt is OK, there is a problem somewhere in the charging system. The problem should be located and corrected as soon as possible. Have the system checked and repaired immediately by the nearest Ssangyong Dealer or Ssangyong Authorized Service Operation. Y220_09C253...
Page 902 ON and should go out if the system is normal. If the “4WD LOW” and “4WD HIGH” warning light come on or blink (IDI Engine), or “4WD CHECK” warning light stays on, have the 4WD system checked at Ssangyong Dealer or Ssangyong Authorized Service Operation. DI engine and gasoline engine equipped vehicle...
Page 903 9C-22 4WD LOW Indicator This indicator comes on when the 4WD LOW mode is se- lected by pushing 4L switch. To shift “4L” position, completely stop the vehicle and always depress the clutch pedal, for manual transmission, or position the selector lever to “N”, for automatic transmission, and select the 4WD switch to “4L”.
Page 904 The air bag system would therefore not be triggered in the event of an accident. Have the air bag system checked with- out delay by a Ssangyong Dealer or Ssangyong Authorized Service Operation. Note If it does not come on, or if it does not go out, or if it flashes or illuminates continuously while driving, it means that there is malfunction in the system.
Page 905 Driving the vehicle with the brake fluid warning light on is dangerous. Have the brake system checked and repaired immediately by nearest Ssangyong Dealer or Ssangyong Authorized Service Operation. Low Fuel Level Warning Light This warning light indicates that the fuel will soon be exhausted.
Page 906 • If this light illuminates while driving, a malfunction of ABS is indicated. In this case the brake system performs its regular function but without the anti-locking capability. Have the system checked by Ssangyong Dealer as soon as possible if this condition occurs.
Page 907 At this moment, the ABS works in a basic Y220_09C270 way. However, make sure to check the vehicle at the nearest Ssangyong Dealer or Ssangyong Authorized Service Operation. SSPS Warning Light This warning light comes on when the SSPS system is defective.
Page 908 • Drain the water from fuel filter immediately after the warning light comes on. If you cannot do that by yourself, visit nearest Ssangyong Dealer or Ssangyong Authorized Service Operation. • For the draining procedures, please refer to “How to drain the water from fuel filter” on next page. After draining the water, press the priming pump until it becomes rigid.
Page 909 9C-28 How to Drain the Water from Fuel Filter (Direct Injection Diesel Engine Equipped Vehicle) 1. Locate the fuel filter in engine compartment. 2. Place the water container under the fuel filter. Y220_09C273 3. Disconnect the connector under the drain plug. 4.
Page 910 This warning light comes on when the ignition switch is turned to ON and goes out if the engine is in normal condition. If the light stays ON, inspect the vehicle by Ssangyong Dealer or Ssangyong Authorized Service Operation. Notice Do not drive with the engine check indicator lamp on.
Page 911 9C-30 MULTI-METER SYSTEM LAYOUT Y220_09C278 1. Barometer 6. Adjustment switch 2. Electronic compass 7. Down switch 3. Speed sensing indicator 8. Power switch 4. Relative altimeter 9. Up switch 5. Altimeter 10. Mode switch INSTRUMENT PANEL AND MULTI-METER CHANGED BY EFFECTIVE DATE REXTON SM - 2004.4 AFFECTED VIN...
Page 912 9C-31 ELECTRONIC COMPASS 1. It indicates 16-direction by intervals of 22.5° according to the vehicle’s driving direction. • Direction: - E: East - W: West - S: South - N: North • When the first equipped to the vehicle or the battery is exchanged, you have to perform calibration by circulating your vehicle.
Page 913 9C-32 SPEED SENSING INDICATOR The flashing interval of the road signs changes gradually ac- cording to the vehicle speed. Flashing intervals by speed ranges Speed Range Flashing Interval Less than 1.8 km/h All “ON” Less than 40 km/h per 1 second Less than 60 km/h per 0.8 second Less than 80 km/h...
Page 914 9C-33 ALTIMETER (ABSOLUTE ALTIMETER) It operates by atmospheric pressure. 0m above the sea level is equivalent to 1013.25 hpa and the altimeter convert the dif- ference between this pressure and atmospheric pressure to altitude and shows by every 20 m. (however, if less than 20 m, it indicates as 0 m) How to Calibrate the Altitude SWITCH...
Page 915 9C-34 RELATIVE ALTIMETER Use this to see the specific area’s altitude; it shows the spe- cific area’s relative altitude based on the current altitude of the vehicle. Mode Setting of the Relative Altimeter 1. Press the “MODE” switch over 0.5 second. 2.
Page 916 9C-35 Removal and Installation 1. Remove the rear cover of the multi-meter. Y220_09C286 2. Unscrew the bolts at rear side of the multi-meter and separate the multi-meter from the instrument panel. Y220_09C287 3. Disconnect the multi-meter connector and remove the multi-meter.
Page 917 MEMO ..................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................
Page 918 9D-1 SECTION 9D SWITCHES Table of Contents SWITCH ................9D-3 Components locator ..........9D-3 FUNCTION AND CIRCUIT OF SWITCHES ....9D-6 Center switches ............9D-6 Left switch panel ............9D-16 Steering wheel remote control switch ...... 9D-19 Seat warmer switch ..........9D-21 MULTI-FUNCTION SWITCH ........
Page 919 9D-3 SWITCH COMPONENTS LOCATOR Center Switches Audio remote control switch Defogger switch Hazard warning switch ESP OFF switch Front fog lamp switch 4WD switch (Full-Time) 4WD switch (Part-Time) Y220_09D133 SWITCHES CHANGED BY REXTON SM - 2004.4 EFFECTIVE DATE AFFECTED VIN...
Page 920 9D-4 Others Outside rearview mirror switch Tailgate window wiper/washer switch Y220_09D134 SWITCHES CHANGED BY EFFECTIVE DATE REXTON SM - 2004.4 AFFECTED VIN...
Page 921 9D-5 Seat Warmer Switch Y220_09D135 Warm the seat in the cold weather for comfortable driving. Press the button to warm the seat, and press it again to stop the operation. Notice • Do not place anything sharp on the seat. This may cause damages to the seat warmer. •...
Page 922 9D-6 FUNCTION AND CIRCUIT OF SWITCHES CENTER SWITCHES ESP OFF Switch “ESP” Indicator ESP OFF switch Y220_09D141 ESP OFF Switch • ESP indicator comes on: When pressing the ESP OFF switch, the ESP function stops and the indicator in instrument panel comes on. •...
Page 923 9D-7 Circuit diagram and connector pin arrangement ESP Switch ESP Unit Y220_09D142 Stopping ESP function with ESP OFF switch If the driving wheels are slipping on the snowy or icy road, the engine rpm may not be increased even when you depress the accelerator pedal, and accordingly, the driver may not start off the vehicle.
Page 924 9D-8 Front Fog Lamp Switch Front fog lamp switch Front fog lamp connector Y220_09D143 To turn on the front fog lamp, push this switch while the light switch is turned on. Pushing this switch again will turn off the fog lamps. SWITCHES CHANGED BY EFFECTIVE DATE...
Page 925 9D-9 Outside Rearview Mirror & Tailgate Glass Defogger Switch Defogger switch Defogger switch connector Y220_09D144 The Outside Rearview Mirror & Tailgate Glass Defogger operates for approx. 12 minutes when pressing this switch while the light switch is turned on. • It stops when pressing the switch again during its operation. If pressing this switch again within 10 minutes after completion of first operation, it will operate for about 6 minutes.
Page 926 9D-10 4WD Switch 4WD indicator Full-Time Transfer Case: only have “4WD LOW” Indicator Part-time 4WD switch Full-time 4WD switch Connector Y220_09D145 • “2H” (2-Wheel drive) Vehicle equipped with automatic transmission This is rear wheel drive with high speed. Use this for 2H →...
Page 927 ON and should go out if the system is normal. If the “4WD LOW” and “4WD HIGH” warning light come on or blink (IDI Engine), or “4WD CHECK” warning light stays on, have the 4WD system checked at Ssangyong Dealer or Ssangyong Authorized Service Operation. IDI engine equipped vehicle...
Page 928 9D-12 Hazard Warning Switch When pressing this switch, both turn signal lights flash. Turn signal light Hazard warning switch and connector Y220_09D149 Circuit diagram and connector pin arrangement Flasher Unit Signal Tail + Tail - Y220_09D150 SWITCHES CHANGED BY EFFECTIVE DATE REXTON SM - 2004.4 AFFECTED VIN...
Page 929 9D-13 Removal and Installation 1. Separate the hazard warning switch. Y220_09D151 2. Disconnect the connector and remove the switch. 3. Install in the reverse order of removal. Y220_09D216 SWITCHES CHANGED BY REXTON SM - 2004.4 EFFECTIVE DATE AFFECTED VIN...
Page 930 9D-14 Digital Clock Y220_09D153 Time Setting 1. S : Setting Button To reset the time by the time signal, press the SET button using a pointer, such as ball-point pen, with the ignition on. For example, if this button is pressed while the time is between 8:00 and 8:29 the display is set to 8:00. If this button is pressed while the time is between 8:30 and 8:59, the display is set to 9:00.
Page 931 9D-15 Removal and Installation 1. Remove the instrument center panel. Y220_09D155 2. Remove the multi-meter and the upper center panel. Y220_09D156 3. Disconnect the connector, unscrew the screws, and remove the digital clock. 4. Install in the reverse order of removal. Y220_09D157 SWITCHES CHANGED BY...
Page 932 9D-16 LEFT SWITCH PANEL Tailgate Window Wiper Switch Switch Wiper switch Washer switch Connector Y220_09D158 Tailgate window wiper switch Tailgate window washer switch Y220_09D159 Y220_09D160 To operate the tailgate window wiper, push the switch. To To spray the washer fluid, push the tailgate washer switch. cancel the operation of the window wiper, push the switch When pressing the switch for more than about 0.6 second, again.
Page 933 9D-17 Outside Rearview Mirror Control Switch Switch Outside rearview mirror folding switch Outside rearview mirror angle adjusting switch Connector Y220_09D161 Outside rearview mirror angle adjusting switch Outside rearview mirror folding switch Y220_09D162 Y220_09D163 • Mirror selection switch To fold the outside rearview mirrors, press the switch for more than 0.5 second.
Page 934 9D-18 Removal and Installation 1. Separate the lower switch panel from the instrument panel. Y220_09D164 2. Disconnect the connector and remove the switch assembly. Y220_09D165 Y220_09D166 SWITCHES CHANGED BY EFFECTIVE DATE REXTON SM - 2004.4 AFFECTED VIN...
Page 935 9D-19 STEERING WHEEL REMOTE CONTROL SWITCH Power switch Mode switch Mute switch Seek up switch Volume up switch Seek down switch Volume down switch Y220_09D167 The steering wheel remote control switch operates the audio system. • POWER switch: Power ON/OFF •...
Page 936 9D-20 Removal and Installation 1. Remove the horn switch on the steering wheel. 2. Unscrew the mounting screws. Y220_09D168 3. Disconnect the connector and remove the steering wheel remote control switch. 4. Remove the ECU under the passenger seat. Y220_09D169 SWITCHES CHANGED BY EFFECTIVE DATE...
Page 937 9D-21 SEAT WARMER SWITCH Seat Warmer Switch Warm the seat in the cold weather for comfortable driving. Press the button to warm the seat, and press it again to stop the operation. Notice Do not operate when the engine is not running. Y220_09D172 Y220_09D173 Circuit diagram and connector pin arrangement...
Page 938 9D-22 Removal and Installation 1. Front Seat Warmer Switch 1-1. Lift up the switch with a special tool from the center console. 1-2. Disconnect the connector and remove the switch. 2. Rear Seat Warmer Switch 2-1. Remove the door panel. 2-2.
Page 939 9D-23 MULTI-FUNCTION SWITCH Y220_09D175 1. Multi-function switch assembly 5. Light switch 2. Turn signal light switch assembly 6. Auto light switch 3. Wiper switch 7. Connector 4. Screw 8. FS switch SWITCHES CHANGED BY REXTON SM - 2004.4 EFFECTIVE DATE AFFECTED VIN...
Page 940 9D-24 CONNECTOR PIN ARRANGEMENT Connector Layout Pin Number Name Turn signal switch (LH) Flasher unit - Power Turn signal switch (RH) Headlamp high beam - Power HS (2) Headlamp switch - Passing Front washer switch Wiper and washer - Ground AUTO Auto wiper Wiper - Parking...
Page 941 9D-25 FUNCTION AND COMPOSITION OF SWITCHES Light Switch Ter. Pos. Y220_09D176 Position AUTO Headlamp Clearance lamp Tail lamp Auto ON/OFF License plate lamp Cluster lamp Fog lamp The fog lamp comes on when the fog lamp switch is operated. High Beam Switch Y220_09D177 To turn on the high beam headlights push the lever towards the instrument panel with the low beam headlights on.
Page 942 9D-26 Passing Light Switch Ter. Pos. HU(Hign) HL(Low) P(Passing) Y220_09D178 To flash the high beam, pull the lever towards the steering wheel and release it. The lever will return to the normal position when released. Turn Signal Light Switch Ter. Turn Hazard Y220_09D179...
Page 943 9D-27 Washer Switch (Windshield Glass) Ter. Pos. Y220_09D180 To spray washer fluid on the windshield, pull the lever towards the steering wheel with the ignition on. When pulling up the lever for less than about 0.6 seconds, the washer fluid is sprayed onto the windshield, but the windows wipers are not operated.
Page 944 9D-28 Automatic Wiper Control Switch The interval of wiper swings can be adjusted by twisting the control knob upward or downward when the windshield wiper switch is in AUTO position. F: Fast interval S: Slow interval Y220_09D182 Auto Light Switch Ter.
Page 945 9D-29 Removal and Installation 1. Disconnect the negative battery cable. 2. Place the steering wheel to straight ahead direction. Unscrew the bolts and remove the horn pad (airbag module). Y220_09D184 3. Mark on the wheel nut and unscrew the nut. 4.
Page 946 9D-30 6. Disconnect the multifunction connector and airbag contact coil connector and remove the contact coil. Y220_09D187 7. Remove the multifunction switch. 8. Install in the reverse order of removal. Y220_09D188 SWITCHES CHANGED BY EFFECTIVE DATE REXTON SM - 2004.4 AFFECTED VIN...
Page 947 9D-31 RAIN SENSING WIPER SYSTEM Overview Rain sensor wiper system is a wiper operation system that sets wiper operation time to fast or slow automatically without driver’s operation by controlling wiper motor drive when the rain sensing unit on the inner upper central wind- shield senses rain.
Page 948 9D-32 Operation Mode Rain sensor wiper control system has AUTO mode (on the conventional INT position) in addition to conventional wiper functions of OFF, MIST, LOW and WASHER. When posi- tioned to AUTO, the rain sensor detects rains on the wind- shield and then controls wiper operation time and wiper op- eration speed to LOW or HIGH automatically.
Page 949 9D-33 4. Automatic low speed AUTO LO mode operates when rains on windshield exceed critical value of AUTO INT and AUTO LO. This critical value has magnetization characteristics that prevents repeating operation between AUTO INT and AUTO LO while accumulating rain. 5.
Page 950 9D-34 9. Instant wipe When wiper system is operated by wiper switch, it wipes windshield once before returning to operation position. This one-time operation happens every time when wiper switch is operated to increase the sensitivity by changing INT volume from lower state (state 1) to higher stage. However, it does not happen when wiper switch is changed into lower sensitivity.
Page 951 9D-35 Outer cover Check the state of rain sensor outer cover. Check whether fixing portion of the cover has loosened and moving so that damaging sensor. And also check whether there are interferences with windshield and head lining. Spring clip To check whether the rain sensor has separated from coupler, remove the outer cover and check spring clip state.
Page 952 9D-36 Description on System Operation Wiping mode 1. Wiper switch is turned on, relay 1 on CONT turns on to rotate the motor clockwise. 2. When “W” and “C” points on the CAM switch are connected during revolution, relay 1 on CONT turns off and then relay 2 turns on to rotate the motor counterclockwise.
Page 953 9D-37 Washer coupled mode 1. When wiper switch is turned on for over 0.6 sec. under IGN SW ignition switch on condition, washer coupled wiper output comes on. WIPER 2. When washer switch is turned off, wiper mode operation LMT ON will be performed 2 times and then return to parking M+ CONTACT position.
Page 954 9D-38 Specifications Item Specification DC 12 V ± 0.3 V Rated voltage Motor Test voltage DC 13.5 ± 0.3 V DC 10 ~ 15 V Operating voltage range Min. operation voltage Below DC 8 V Over 500 V mega 1 M Insulation resistance Lock test Torque...
Page 955 9D-39 AUTO LIGHT SYSTEM Overview Auto light control is a system that turns on/off position lamps and headlamps automatically. Auto light sensor unit on the instrument panel upper (passenger) detects surrounding brightness and then turns on or off position lamps and headlamps automatically if light switch is in AUTO mode even when the driver does not operate light switch.
Page 956 9D-40 Auto Light Sensor Unit Terminal 1. System power supply 2. Auto light switch 3. Reserved 4. Headlamp relay 5. Position lamp relay 6. System ground Y220_09D200 Auto Light Operation and Turning on Condition Switch operations by function 1. Turn on the ignition switch and operate the multi-function switch in the order of OFF → position lamp → headlamp →...
Page 957 9D-41 Operational Characteristics IGN SW Within OFF range Within ON AUTO light SW Position lamp Headlamp Y220_09D201 However, the condition is position lamp and headlamp are within ON and OFF ranges. T1: 3 ± 1.0 sec T2: 500 ± 100 msec Inspection Locate the multi-function switch to AUTO position and cover the auto light sensor on the upper instrument panel (in front of...
Page 958 9D-42 SEAT MEMORY SWITCH SEAT POSITION MEMORY SETTING AND OPERATION Y220_09D203 1. “SET” switch 2. “STOP” switch 3. Position (1, 2, 3) switch Up to 3 different drivers, the memory setting of seat position is available. Each driver can set his/her own driver’s seat and outside rearview mirrors positions and it will be stored in the computer.
Page 959 9D-43 Storing Memory Settings 1. Place the selector lever in “P” (automatic transmission) or “N” (manual transmission) position, and apply the parking brake with the ignition switch “ON”. 2. Adjust the driver’s seat and outside rearview mirrors. 3. Press the “SET” button. Indicating light on the button will come on and beep sounds.
Page 960 9D-44 FUNCTION DESCRIPTION Seat Position and Warmer Unit This unit is installed under the driver’s seat and functions as follows: - Memory return of driver’s and passenger’s seat - Memory return of outside rearview mirror - Warming up the driver’s and passenger’s seat - Folding the outside mirrors Specifications Description...
Page 961 9D-45 Storing Memory Ignition switch P/N switch or parking brake s w i t c h Over 0.1 sec SET button Within 5 seconds Memory allowable condition Buzzer (unit inside) Over 0.1 sec Position switch (1, 2, 3) Memory Return 1.5 sec SET button Position switch...
Page 962 9D-46 Removal and Installation 1. Disconnect the negative battery cable. 2. Remove the driver’s door panel. Y220_09D207 3. Unscrew the switch mounting screws from the door panel. Y220_09D208 4. Remove the memory switch. 5. Install in the reverse order of removal. Y220_09D209 SWITCHES CHANGED BY...
Page 963 9D-47 WINDOW SWITCH SYSTEM LAYOUT Front (Driver’s) Window Switch Y220_09D210 Passenger’s/Rear Window Switch Passenger’s side Rear side Y220_09D211 SWITCHES CHANGED BY REXTON SM - 2004.4 EFFECTIVE DATE AFFECTED VIN...
Page 964 9D-48 Removal and Installation 1. Remove the door panel. Y220_09D212 2. Unscrew the switch mounting screws and remove the switch. 3. Install in the reverse order of removal. Y220_09D213 SWITCHES CHANGED BY EFFECTIVE DATE REXTON SM - 2004.4 AFFECTED VIN...
Page 965 9G-1 SECTION 9G LAMPS Table of Contents LAMP LOCATIONS ............9G-3 Exterior lamps ............9G-3 Specifications ............. 9G-4 MAINTENANCE AND ADJUSTMENT ......9G-5 Headlamp aiming ............9G-5 Measurement of headlamp aiming ......9G-7 TROUBLE DIAGNOSIS ..........9G-8 EXTERIOR LAMPS ............9G-9 INTERIOR LAMPS ............
Page 966 9G-3 LAMP LOCATIONS EXTERIOR LAMPS Y220_09G325 1. Headlamp - Low beam 8. Tail lamp 2. Headlamp - High beam 9. Stop lamp 3. Clearance lamp 10. Turn signal lamp 4. Turn signal lamp 11. Back-up lamp 5. Fog lamp 12. Rear deflector 6.
Page 967 9G-4 SPECIFICATIONS Description Specification Description Specification Rear combination Headlamp Low beam 55W x 1 Back-up lamp 27W x 1 lamp High beam 55W x 1 Rear Deflector Clearance lamp 5W x 2 License plate lamp License plate lamp 5W x 2 Front combination Fog lamp 27W (H27W)
Page 968 9G-5 MAINTENANCE AND ADJUSTMENT HEADLAMP AIMING An approved beam setting device should be used for a correct headlamp aiming. Make sure to follow the operating instructions provided by the manufacturer. Headlamp aiming requirements: parking on a flat surface specified tire pressure, one passenger (driver, 65 kg), spare tire loaded, OVM tools loaded (unlade all other loads) If not available to use the beam setting device, adjust the headlamp aiming with a screen.
Page 969 9G-6 When Using a Screen (unit: mm) 1. Install the screen (2 m x 1.5 m) in front of the headlamps by 3 meters and align the center lines of the vehicle and the screen. Y220_09G329 2. Align the horizontal line through the headlamp center and the center line of the screen.
Page 970 9G-7 MEASUREMENT OF HEADLAMP AIMING Y220_09G333 LAMPS CHANGED BY REXTON SM - 2004.4 EFFECTIVE DATE AFFECTED VIN...
Page 971 9G-8 TROUBLE DIAGNOSIS Symptom Cause Action Inoperative one side lamp Burnt out bulb Replace bulb Defective socket or wiring, or poor ground Replace if needed (all external lamps) Inoperative headlamps Burnt out bulb Replace bulb Defective fusible link Replace fusible link Defective headlamp relay Check for relay Defective light switch...
Page 972 9G-9 EXTERIOR LAMPS Headlamp (High beam, Low beam, Clearance lamp) Side turn signal lamp Front combination lamp (Turn signal lamp, Fog lamp) License plate lamp Rear combination lamp High mounted stop lamp (Tail lamp, Stop lamp, Turn signal lamp, Stop lamp) Y220_09G334 LAMPS CHANGED BY...
Page 973 9G-10 Headlamp - Removal and Installation 1. Disconnect the negative battery cable. 2. Remove the radiator grille. 3. Remove the headlamp mounting bolts. Y220_09G335 4. Disconnect the connector and remove the headlamp assembly. Y220_09G336 5. Disassemble the bulb cover, connector and bulb. Y220_09G337 6.
Page 974 9G-11 Front Turn Signal Lamp/Fog Lamp - Removal and Installation 1. Disconnect the negative battery cable and remove the headlamp. 2. Unscrew the nuts and disconnect the lamp connectors (front turn signal lamp/fog lamp). Y220_09G338 3. Remove the lamp assembly. Y220_09G339 4.
Page 975 9G-12 Rear Combination Lamp - Removal and Installation 1. Disconnect the negative battery cable. 2. Remove the rear combination lamp mounting screws. Y220_09G341 3. Disconnect the rear combination lamp connector and remove the lamp assembly. Y220_09G342 4. Remove the bulb from the removed lamp assembly. 5.
Page 976 9G-13 Side Turn Signal Lamp - Removal and Installation 1. Push the side turn signal lamp forward and pull in the rear side of the lamp to separate. Y220_09G345 2. Disconnect the connector and remove the lamp. Y220_09G346 High Mounted Stop Lamp - Removal and Installation 1.
Page 977 9G-14 INTERIOR LAMPS Glove box lamp Courtesy lamp 1. Front room lamp 2. Center room lamp 3. Rear room lamp Y220_09G349 LAMPS CHANGED BY EFFECTIVE DATE REXTON SM - 2004.4 AFFECTED VIN...
Page 978 9G-15 Door Lamp - Removal and Installation 1. Disconnect the negative battery cable. 2. Detach the door trim and disconnect the lamp connector. Y220_09G350 3. Unscrew the mounting screws and remove the lamp. 4. Install in the reverse order of removal. Y220_09G351 Glove Box Lamp - Removal and Installation...
Page 979 9G-16 Interior Lamp - Removal and Installation Front Lamp 1. Separate the lamp cover and remove the bulb. Y220_09G353 2. Unscrew the mounting screws and separate the front room lamp housing. Y220_09G354 3. Disconnect the connector and remove the lamp housing. 4.
Page 980 9G-17 Center/Rear Lamp 1. Separate the lamp cover and remove the bulb. Y220_09G356 2. Unscrew the mounting screws and separate the front room lamp housing. 3. Disconnect the connector and remove the lamp housing. 4. Install in the reverse order of removal. Y220_09G357 LAMPS CHANGED BY...
Page 981 MEMO ..................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................
Page 982 9H-1 SECTION 9H WIPER & WIPER MOTOR/HORN Table of Contents COMPONENTS LOCATOR ..........9H-3 Removal and installation ........... 9H-4 INSPECTION ..............9H-7 HORN ................9H-13 WIPER & WIPER MOTOR/HORN CHANGED BY REXTON SM - 2004.4 EFFECTIVE DATE AFFECTED VIN...
Page 983 9H-3 COMPONENTS LOCATOR Y220_09H358 1. Wiper blade 4. Wiper blade 2. Wiper motor and linkage 5. Wiper motor 3. Washer reservoir assembly WIPER & WIPER MOTOR/HORN CHANGED BY REXTON SM - 2004.4 EFFECTIVE DATE AFFECTED VIN...
Page 984 9H-4 REMOVAL AND INSTALLATION Front Wiper Assembly Notice Disconnect the negative battery cable and make sure that the “A101” switch is at “OFF” position. 1. Open the hood and disconnect the washer hose. Y220_09H359 2. Remove the wiper arms. Y220_09H360 3.
Page 985 9H-5 4. Disconnect the wiper motor connector and remove the wiper linkage assembly. Y220_09H362 Y220_09H434 5. Unscrew wiper motor mounting bolts from the removed linkage and separate the linkage and motor. 6. Install in the reverse order of removal. Motor mounting bolt 7 ~ 11 Nm Linkage nut 4 ~ 6 Nm...
Page 986 9H-6 3. Disconnect the wiper motor connector and unscrew the mounting bolts. 4. Remove the wiper motor assembly from the tailgate. 5. Install in the reverse order of removal. Wiper motor assembly Motor bolt 7 ~ 11 Nm Motor bracket bolt 7 ~ 9 Nm Rear wiper blade Mounting nut...
Page 987 9H-7 INSPECTION Front Wiper Motor Speed 1. Disconnect the wiper motor connector. P(Parking) 2. Connect the positive battery terminal to No. 3 terminal IGN(+) and the negative battery terminal to No. 6 terminal. 3. Check if the wiper motor operates with “LO” speed. 4.
Page 988 9H-8 Passenger’s Door and Rear Sub Rear Switches 1. Remove the switch and check the continuity between terminals. Passenger’s Y220_09H370 Power Window Motor Connect the motor terminal to battery and check if the motor operates smoothly. And, change the polarity conversely and check if the motor operates smoothly.
Page 989 9H-9 Tailgate and Side Quarter Glass Defogger Press by hand against to grid Notice Test probe To prevent from damage, wrap the tester probe end with tin foil and check the circuit for open by moving the tester probe along the grid line. Tin foil Heated wire Y220_09H372...
Page 990 9H-10 4) Move the test leads around suspected area to check the circuit for open. The broken point shows the Voltage is changed around open circuit voltage changes. Voltage (-) Terminal Y220_09H376 2. Turn the defogger switch “OFF” and check as follows. Measure the resistance between the terminals and center When checking at (-) terminal side (No damaged grid line)
Page 991 9H-11 1. Disconnect the negative battery cable. 2. Disconnect the tailgate defogger connector. Y220_09H379 Y220_09H380 3. Inspect the tailgate defogger grid lines. 4. Mark the grid line break on the outside of the glass with a wax pencil or a crayon. 5.
Page 992 9H-12 9. Heat the repair area for 1 to 2 minutes. Notice The grid line repair material must be cured with heat heat. In order to avoid heat damage to the interior trim, protect the trim near the repair area where heat will be applied.
Page 993 9H-13 HORN 1. Disconnect the negative battery cable. 2. Remove the radiator grille and headlamp assembly. Y220_09H311 3. Disconnect the horn connector. Y220_09H312 4. Unscrew the mounting bolts and remove the horn. 5. Install in the reverse order of removal. If required, adjust the tone with adjusting screw.
Page 994 MEMO ..................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................
Page 995 SECTION HVAC SYSTEM CONTENTS FFH/PTC SYSTEM ............10A HEATER & VENTILATION SYSTEM ......10B A/C SYSTEM..............10C...
Page 996 10A-1 SECTION 10A FFH/PTC SYSTEM Table of Contents FUEL FIRED HEATER (FFH) SYSTEM ....... 10A-3 Components locator ..........10A-3 System layout............10A-4 Trouble diagnosis ..........10A-13 Removal and installation ........10A-25 POSITIVE TEMPERATURE COEFFICIENT (PTC) SYSTEM ..................10A-30 Components locator ..........10A-30 COMPONENTS ............
Page 997 10A-3 FFH SYSTEM FUEL FIRED HEATER (FFH) SYSTEM In fuel fired heater system equipped vehicle (D27DT engine equipped), when the ambient temperature and coolant temperature is low, the burner installed in engine cooling system increases the temperature of coolant that flows into heater by firing diesel fuel for a certain period of time.
Page 998 10A-4 SYSTEM LAYOUT Y220_10A002 1. FFH assembly 8. Temperature sensor assembly 2. Water pump and bracket assembly 9. Intake hose 3. FFH No.1 bracket assembly 10. Fuel pipe No.1 4. FFH No.2 bracket assembly 11. Fuel pipe No.2 5. Silencer and pipe assembly 12.
Page 999 10A-5 Exploded View Y220_10A003 FFH/PTC SYSTEM CHANGED BY REXTON SM - 2004.4 EFFECTIVE DATE AFFECTED VIN...
Page 1000 10A-6 1. Jacket 18. Surface sensor with cable 2. Jacket cover 19. Controller connector - 14-pin connector (waterproof) 3. Combustion air fan 20. Pressure spring for surface sensor 4. Combustion chamber 21. Pressure spring for control and overheating sensor 5. Combustion chamber with flame tube 22.

Save PDF