Fluid - A/T: Service and Repair

Automatic Gearbox, JATCO - Fluid Level Check


VERIFY PROPER PLUG IS REMOVED FOR LEVEL CHECK


CAUTION:
Because of the similarity to other plugs and fasteners on the transmission, the potential for loosening an incorrect fastener, instead of the level plug, exists. There is a risk for internal transmission damage if the improper fastener is removed.

- Removal of the reduction gear brake band bolt can cause total loss of drive or a substantial reduction in the performance of the transmission

- Removal of the parking pawl rod plate retaining bolt (located next to the XYZ switch) will result in problems / gear lever movement restrictions.

Under NO CIRCUMSTANCES must these items be removed or loosened. Doing so will invalidate any warranty claim made. Damage caused by improper service procedures is NOT warrantable.

Check and top-up fluid

WARNING:
Avoid excessive skin contact with mineral oil. Mineral oils remove the natural fats from the skin, leading to dryness, irritation and dermatitis.

1. Position vehicle on ramp.

2. Apply handbrake and position chocks under front and rear wheels.


3. Remove underbelly panel, following this sub-repair -->

Remove







2. Remove 2 screws securing bumper valance to underbelly panel brackets.
3. Remove 4 screws securing wheel arch liners to bumper valance, it fitted.
4. Remove 2 bolts securing rear of underbelly panel.
5. Remove 6 bolts securing underbelly panel frame.
6. Remove underbelly panel.

Refit
1. Position underbelly panel.
2. Fit bolts securing underbelly panel frame and tighten to 45 Nm (33 lbf.ft).
3. Fit bolts securing rear of underbelly panel and tighten to 8 Nm (6 lbf.ft).
4. Fit and tighten screws securing wheel arch liners to bumper valance, if fitted.
5. Fit and tighten screws securing bumper valance to brackets.
6. Remove stands and lower vehicle.
End sub-repair.



4. Connect TestBook/T4 to monitor gearbox fluid temperature.

CAUTION:
The gearbox fluid level must only be checked when the temperature of the fluid is between 35°C and 45°C The reading obtained will be incorrect if the fluid is outside this temperature range.

5. Start engine, move selector lever from "P" through all gear positions, pausing in each gear position for 2-3 seconds and return to "P" position.

6. Clean area around level plug.

Level Plug:

7. With the engine still running remove level plug using a 5 mm Allen socket and allow any excess fluid to drain off.

CAUTION:
There are a number of similar fixings/plugs on the underside of the gearbox. It is imperative that the correct plug is removed prior to checking the level. Removing the wrong fixing/plug could result in internal damage to the gearbox.


8. If no fluid loss is apparent when level plug is removed:

Filler Plug:

9. Remove filler plug

9a. Add fluid until it just runs from level plug aperture.


9b. Remove the oil level plug and collect excess ATF in a clean container.






9c. When draining of ATF stops (Figures 2-4), install a new drain plug/washer assembly and tighten to 13.5 - 16.5Nm (9-12 lbf.ft.)

When topping up after a new air blast cooler (Td4 hot climates) has been fitted, an extra 420 cc of fluid is required. The fluid must also reach a temperature of 80°C (176°F) to allow the switch on the cooler to open.

10. Move selector lever from "P" through each gear position and return to "P" , allowing any excess fluid to drain off.

11. Fit new level plug and tighten to 14 Nm (10 lbf. ft).

12. Clean and fit filler plug.

13. Disconnect TestBook/T4.

14. Fit underbelly panel.