Possible transmission issue in my new 93 HDJ81 - help/suggestions?

[asutherland]

Hi,

Radd in Duncan is currently investigating some options, but I thought I would post in here in case someone else has seen exactly my issues or has a suggestion to try.

A few intermittent problems with my transmission (I assume) have cropped up over the last few weeks.. I've only had my truck on the road for a month and a half, so...

Details:

• 1992 build month 09 HDJ81
• It has the electronic automatic transmission
• 163,000 KM

Symptoms Observed:

• Intermittant: on trails and off road, there have been a few times where I start driving and it feels like the trans is slipping. The engine tries hard, but barely moves the vehicle forward. It seems to happen when going up hills, but the hills are NOT extreme in any way. By dropping it into Neutral, then back into gear, it starts acting normal again. Once, I just paused for about 5 seconds and pressed the accel again and it acted normally.
• Intermittant: Once and a while in 4 low, the gearing is off. For example, in 4 low w/2nd gear selected, sometimes it will just CRAWL as if I was in the lowest gear possible. Then I'll stop for a second, start driving again, and it feels like I'm now in a higher gear (can go faster and RPMS are down). This seems very random and intermittant.
• Once: on a mountain pass on a forest service rd (nothing extreme, but lots of up hill travel) the "AT Temp" light came on. I immediately pulled over and let it cool for a half hour, then drove the rest of the way without incident.
• After the above incident, I flushed (proper flushing, not just drain and refill) the ATF with new. Fluid seemed OK, but I didn't take the chance. Also, Radd Cruisers (thx Jay) has installed an aftermarket ATF cooler.
• Consistant: Torque converter lock does not happen on the highway. Not ever since I owned the vehicle.
• Shifting between gears and downshifting seems fine, nice and smooth and quick.

Suggestions? help? anyone? Any help would be appreciated, but please don't flaim or use FUD as I'm not a mechanic.

Thanks kindly,
Andrew

 

[96r50]

Hey Andrew,

Is that the A442F transmission like the 93-94 FZJs have? If so, there are a few documented cases of the shift solenoids acting up/failing and causing some symptoms similar to yours. I believe cruiserdan and spdwaver1 both had this problem and started threads about it. Take a look at their experience and see if it matches up.

At least you're in the right end of the country for cruiser shops!

 

[asutherland]

Hey Andrew,

Is that the A442F transmission like the 93-94 FZJs have? If so, there are a few documented cases of the shift solenoids acting up/failing and causing some symptoms similar to yours. I believe cruiserdan and spdwaver1 both had this problem and started threads about it. Take a look at their experience and see if it matches up.

At least you're in the right end of the country for cruiser shops!

Hey Adam,

Yup, you are correct I believe. A442F

 

[96r50]

Hey Adam,

Yup, you are correct I believe. A442F

Get your reading goggles out!

https://forum.ih8mud.com/80-series-tech/351009-1993-fzj80-transmission-slips-forward-gears.html
https://forum.ih8mud.com/80-series-tech/15662-transmission-problem.html
https://forum.ih8mud.com/80-series-tech/348943-transmission-shifting-issue.html

 

[asutherland]

Get your reading goggles out!

https://forum.ih8mud.com/80-series-tech/351009-1993-fzj80-transmission-slips-forward-gears.html
https://forum.ih8mud.com/80-series-tech/15662-transmission-problem.html
https://forum.ih8mud.com/80-series-tech/348943-transmission-shifting-issue.html

Interesting. All 3 theads came to the same conclusion - shifting solenoids needed replacing. (yes, I read the whole 6 pages of the first thread)

All the symptoms seem similar, maybe with the exception that my torque converter doesn't seem to lock. Possibly 2 issues here then?

Did I read correctly, and the "O/D Off" light will flash while driving if there is an issue, giving the transmission code? Or do I need to initiate the troubleshooting mode somehow. I haven't seen it flash yet, and I did check, the light itself and switch work fine.

 

[spdwaver]

Interesting. All 3 theads came to the same conclusion - shifting solenoids needed replacing. (yes, I read the whole 6 pages of the first thread)

All the symptoms seem similar, maybe with the exception that my torque converter doesn't seem to lock. Possibly 2 issues here then?

Did I read correctly, and the "O/D Off" light will flash while driving if there is an issue, giving the transmission code? Or do I need to initiate the troubleshooting mode somehow. I haven't seen it flash yet, and I did check, the light itself and switch work fine.

My O/D Off light did not always flash concurrently with the problems I was experiencing.

Read the codes. You may get a code 62 if the solenoids are at all problematic. But, as I pointed out in my thread - even after performing the electricity/air test on the solenoids - did not prove the solenoids inoperable or faulty.

Only when I replaced the solenoids did the problem go away.

Now, there was a more recent thread from Hatman406080 in which explained the same problem, same codes. After he installed the new solenoids, I called and asked him how it is running. He said that the problem went away briefly, but did not resolve his shifting issue. I am not sure what subsequent diagnostics have revealed since then, but just be advised that solenoid replacement will not always guarantee a fix here.

 

[Radd Cruisers]

This is an electronic A442F we are talking about here.

Shifting the gears manually over-rides the computer and the gears shift hydraulically.

This, to me, sounds like a solenoid fault. Since there's no fault showing via the OD light, it may not be getting picked up by the ECU.

The repair procedure might be a little hit and miss on this one, and will probably involve replacing shift solenoids.

~John

 

[Tapage]

You can check the solenoids by removing the tranny oil pan ( you will see 'em ) and by FSM

Did you perform an stall test . ? that will let you know if your TC it's ok and overal shape of your tranny discs.

 

[96r50]

This is an electronic A442F we are talking about here.

Shifting the gears manually over-rides the computer and the gears shift hydraulically.

This, to me, sounds like a solenoid fault. Since there's no fault showing via the OD light, it may not be getting picked up by the ECU.

The repair procedure might be a little hit and miss on this one, and will probably involve replacing shift solenoids.

~John

Same transmission as the 93-94 USDM trucks that have similar symptoms Good luck with the repair!

 

[asutherland]

So I definitely found a way to make the issue happen. Stop while in -D- on a slight hill facing upwards, then start to accelerate. Doesn't want to go anywhere. Drop it into 1st gear, accelerate, works fine.

 

[Tapage]

So I definitely found a way to make the issue happen. Stop while in -D- on a slight hill facing upwards, then start to accelerate. Doesn't want to go anywhere. Drop it into 1st gear, accelerate, works fine.

that sounds like the tranny won't downshift to 1st ..when the lever it's in D

 

[spdwaver]

So I definitely found a way to make the issue happen. Stop while in -D- on a slight hill facing upwards, then start to accelerate. Doesn't want to go anywhere. Drop it into 1st gear, accelerate, works fine.

In this way I was able to reproduce the problem as well, but it did not matter whether I was on an incline, flat or decline at the time.

Edit: In other words, it may be attempting to start out in second or third gear...until you drop it into first.

 

[busmup808]

I have my trans and t-case from my 94 in my garage. Has 161K

 

[asutherland]

Can someone link me on how to retrieve the transmission codes? Something about jumping a connector at TT? I've been searching but there's a lot of info, most of it is for engine codes. And the FSM seems to not have it. It's from 1990... anyone have a pdf of a newer one?

 

[Jack G. Nichols]

Mine does this once or twice a year. I give it a good cussing, and it seems fine for another year.

I will replace the solonoids if it repeats with any regularity.

I just did a drain and refill, that might either help, or stir up some junk, we will see.

Love my truck.

 

[asutherland]

Daniel and I got the codes.

#62 - solenoid #1
#64 - lockup solenoid
#65 - timing solenoid (?)

We checked the resistance of the solenoids directly on the transmission housing plug (to rule out the harness and connectors) and it was way too high on solenoid #1 and the lockup solenoid. (about 2x the spec)

Next task will be to open the pan and see if it's just as bad on the actual solenoids themselves.

 

[asutherland]

Update:

We drained the ATF, removed the pan, removed the solenoids #1 and locking (S1 and SL in the FSM) and verified - the resistance on the 2 bad solenoids was roughly 2x what was in spec. Rather than ~13 ohm it was more than 28.

Picked up S1 from Radd yesterday, put it in, reattached the pan and refilled the ATF. Took it for a drive, and WOW - no more issue! Starting on a slight hill, slowly pressing the gas, it just... moves forward effortlessly instead of straining and revving high.

Radd didn't have an SL in stock, so they've ordered for me and we'll just repeat the process again in a week or so. Easy when you have the cork gasket. Then I'll have lockup too Yahoo!

Thanks for the help everyone and certainly mention this thread when people are searching for " transmission, issue, lockup, solenoid, slip, A442F, etc"

 

[96r50]

Glad you got it sorted out!

 

[asutherland]

Here's the little fxxxer that we replaced: Solenoid #1

 

[simonliew]

l have the same problem on one of my 81,now l know what to do.
Simon