General information about automatic transmission (2WD) Note: the type of automatic transmission is given on an aluminum plate located on the rear wall of the engine compartment. operation of the automatic transmission, replacement of fluids in the automatic transmission,...
A132L planetary gearbox planetary gear (A132L): 1 - intermediate drive gear, 2 - epicycle of the rear planetary gear set, 3 - first gear and reverse brake (IN 3 ), 4 - freewheel №2 (F 2 ), 5 - second gear brake (IN 2 ), 6 - forward clutch...
Hydraulic part of the control system (2WD) The control system includes: oil pump, valve block, solenoid valves (solenoids), hydraulic accumulators, clutches and brakes. The main pressure in the system is created by the oil pump, it is regulated depending on the...
Electrical part of the control system (A240E, A241E and A245E) The electrical control system for the automatic transmission provides extremely precise control of the shift and torque converter lock-up timing depending on the driving conditions and engine operation. In addition, the...
General information about automatic transmission (4WD) The A540H automatic transmission consists of a torque converter with a lock-up clutch, a 3-speed planetary gearbox with an overdrive planetary gear set, a transfer case and a control system consisting of hydraulic and...
Hydraulic part of the control system (4WD) Transmission The control system includes: oil pump, valve block, solenoid valves (solenoids), hydraulic accumulators, blocking clutches and brakes. The main pressure in the system is created by the oil pump, it is...
Electrical part of the control system (4WD) The electrical control system for the automatic transmission provides extremely precise control of the shift and torque converter lock-up timing depending on the driving mode and engine operation. In addition, it allows...
Fluid Temperature Alarm System The electronic control unit monitors the temperature of the working fluid using a temperature sensor. The temperature of the working fluid may become excessively high when the vehicle is operated under increased load,...
Checking and adjusting the throttle control cable 1. Fully depress the accelerator pedal and make sure that the control lever rests against the adjusting screw 2. Push the accelerator pedal all the way down and loosen the adjusting nuts. 3. Adjust the cable so that the...
Checking and adjusting the automatic transmission control rod 1. When translating the selector from position "N" to other positions it should move freely, to the indicator it should indicate the selected position correctly. If the indicator does not show the selected position...
Check and adjustment of the switch of prohibition of start of the engine 1. Make sure that the engine can only be started when the selector is in the "N" or "R". 2. If the engine can be started in other positions, then adjust the engine start inhibit switch. A) Loosen the bolts of the start...
Checking the idle speed (range N) Check idle speed in selector position "N" and the air conditioner turned off. Idle speed: A241L: 750-850 rpm A240E (4A-FE): 650-950 rpm A241E until 1996: 3S-FE: 450-750 rpm Models since 1996: 3S-FE: 600-700 rpm 4A-FE,...
Checkpoint diagnostics — general information Note: Malfunctions that occur in the gearbox can be associated either with the engine, or with the control system, or with the gearbox itself. Therefore, before starting the check, it is necessary to determine the area...
Self-diagnosis system (A240E, A241E, A245E and A540H) General information 1. The self-diagnosis function is built into the automatic transmission electronic control unit. With the help of the overdrive off indicator, the system can warn the driver of a malfunction in the...
Checking the overdrive off indicator 1. Turn on the ignition. 2. The indicator should be on when the overdrive switch is in the position "OFF". 3. Move the overdrive switch to the "ON": The indicator should turn off. If the indicator flashes, then this is...
Reading fault codes automatic transmission 1. Turn on the ignition and set the overdrive switch to "ON". Attention: do not start the engine. 2. Short the leads "THOSE 1 " And "E 1 " diagnostic socket. 3. Read and determine the fault code by the number of blinks...
Troubleshooting automatic transmission Note: When trouble codes appear (2WD models) No. 37, 38, 42, 61, 62 and 63 or (4WD models) No. 62, 63 indicator will flash immediately to warn the driver. However, a collision or impact may cause the indicator to stop...
Gear shift check Note: This check allows you to determine if the cause of the malfunction is an electrical or mechanical problem in the transmission. 1. Disconnect the solenoid valve block connector. A241L, A240E, A241E A245E A540H 2....
Checking the automatic transmission and engine control unit Attention: do not open the cover of the control unit unnecessarily, (if you touch the terminal of the integrated circuit, it can be damaged by static electricity). Fault #1: No switching 1. Warm up the engine to a...
Checking the voltage at the output «TT» 1. Checking the signal from the throttle position sensor. A) Turn on the ignition. Do not start the engine. b) Connect a voltmeter to the diagnostic connector "TT" And "E1". Models up to 1996 Models since 1996 V) While...
Electrical components, automatic transmission A241L Location of electrical elements (A241L): 1 - overdrive switch, 2 - overdrive solenoid valve, 3 - engine start inhibit switch. 1. Check the start inhibit switch. Check continuity between the connector pins shown in the...
Checking the mechanical systems of automatic transmission Fully braked test (stall test) This test checks the performance of the gearbox and engine by measuring the speed at maximum load on the ranges "D" And "R". Note: the test should be carried out at normal operating...
Hydraulic test automatic transmission Main line pressure check 1. Preparation: A) Warm up the transmission fluid to operating temperature (50-80°C) b) Unscrew the service plug of the gearbox housing and connect a pressure gauge in its place. Attention: the...
Center Differential Lock Clutch Test (A540N) 1. Preparation: A) Warm up the transmission fluid to operating temperature (50-80°C). b) Unscrew the service plug of the gearbox housing and connect a pressure gauge in its place. Attention: carry out the check with two...
Road test automatic transmission Note: before starting the check, warm up the transmission fluid to a temperature of 50-80°C. Range check "D" Translate the selector to a range "D" and depress the accelerator pedal all the way. 1. Check the presence of...
Throttle control cable Removing 1. Disconnect the control cable from the throttle sector or injection pump lever. For diesel engines For petrol engines 2. Remove the engine start stop switch lever. A) Disconnect the throttle valve control rod...
Speed sensor rotor (A240E, A241E until 1996) Removing Note: Install in the reverse order of removal. 1. Remove the speed sensor and the speed sensor rotor. A) Remove the protective plate and speed sensor. Tightening torque when installing 5.4 Nm. b) Remove the...
Speed controller (A241L, A132L) Removing Note: Install in the reverse order of removal. 1. Disconnect the speedometer cable. 2. Remove the speed control cover and o-ring. A241L A132L 3. Remove speed controller and thrust washer A132L: 1 - adapter, 2 -...
Speed sensor No. 2 (A245E) Replacement 1. Disconnect the sensor connector. 2. Remove speed sensor #2. A) Loosen the bolt and remove the sensor. b) Remove the O-ring from the sensor. 3. Install speed sensor #2. A) Lubricate the new O-ring with...
Drive shaft seals (front wheel drive) Removing 1. Drain the transmission fluid. 2. Remove the lower engine protection. 3. Remove the right and left drive shafts. 4. Remove the left and right drive shaft seals using a puller. Installation 1. Install the left...
Replacing the output shaft seal (rear wheel drive) (A540N) 1. Drain the transmission fluid. 2. Remove cardan shaft. 3. Using a puller, remove the output shaft seal. 4. Install the output shaft seal A) Lubricate the seal lip with grease b) Using a mandrel, install a new oil...
Removal and installation of a transmission (2WD models, up to 1996) 2WD models prior to 1996: 1 - air intake and air filter, 2 - battery, 3 - exhaust pipe, 4 - left drive shaft, 5 - beam of the central engine mount, 6 - protection of the beam, 7 - engine protection casing, 8 - cross...
Removal and installation of a transmission (2WD models, since 1996) 2WD models since 1996 1 - cotter pin, 2 - locknut cap, 3 ~ left drive shaft, 4 - retaining ring, 5 - starter motor, 6 - left engine mount bracket, 7 - air intake and air filter, 8 - rear support bracket engine mounts, 9...
Gearbox assembly (4WD models) Note: Removal and installation of the gearbox for 4WD models is carried out in the same way as removal and installation for 2WO models, taking into account design features. 4WD Models: 1 - center bracket, 2 - gearbox, 3...
Checking the torque converter and torque converter drive plate 1. If the transmission fluid is contaminated, flush the torque converter and fluid cooler 2. Checking the freewheel. A) Install the special tool in the inner race of the freewheel. b) Install the special tool so that...
Transfer case (only for A540H) Transfer case: 1 - holder of the cover of the crankcase of the transfer case; 2 - sealing ring; 3 - locating pin; 4 - driven gear of the pump drive; 5 - sealing ring; 6 - filter; 7 - shaft of the drive gear of the main...