New FJ80 owner, Transmission issue

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Cross solunoids off, That wasnt it. I pulled apart the barrel connector and it was indeed corroded. I also managed to break a pin which basically turned to dust as I tried to clean it. It was on the NSS side. So, Progress? Lol the saga continues tomorrow.
 
If by "pin" you mean one of the terminals inside the connector housings, you can buy them by the pound (or individually, if you want), from Ballenger Motorsports (others, too, but I'd recommend Ballenger). You also need a dedicated terminal crimping tool; your wire stripper won't cut it.

Toyota lists the terminals as Type 2.3–II. They are Sumitomo 2.3–mm wide terminals. Do not buy the repair wires listed in the Wire Harness Repair Manual (RM1022E); they are terminals, crimped onto 16–ga wires. Not what you want.

The female terminals are Ballenger part number CONN-11856
The male terminals are Ballenger part number CONN-100069

FWIW, the connector housings are Sumitomo; don't buy Yazaki terminals, they are not guaranteed to fit.
 
Update time, I found a NSS and swapped it out. I also cleaned the connector and it looks good. Bad news, Same issues. Flickering gear selections on the dash and starts sluggish in D. Im now chasing a wire issue I think? Was really hopeful this would be solved.
 
A potential problem with cleaning the terminals' ends in the joining connector housings is that corrosion may have made its way to the terminal/wre conenction itself. The only way to be sure is to meter the wire capacity (ohms) from the terminals to the opposite end (the ECM behind the glovebox).

Having said that, I would reseve that check for the last resort. You can get to both ends by removing the console and working across the top of the transmission, through the floor penetration, but it'll take work.

Before doing that, if you're sure the NSS and conenctor housings are sound, I'd look at the transmission harnesses themselves. One feeds the NSS and though it the solenoids and the other is primarily the transfer case sensor pigtail. The problem is that Toyota mixed the wires in both sub–harnesses and they cross again at their connections to the ECM. It's not impossible to do, but I mention this because you have to check both sub–harnesses, not just the one connected directly to the NSS.

You also really need to have a verified EWD in hand while you work. And, to make matters worse, there are undocumented wire (color) changes in the harnesses.
 
HOPEFULLY SOLVED: I decided to retrace my efforts and noticed I may have pulled the wrong box at the start of my troubleshooting. It was pretty clear to me that I failed to pull the TCM and when I did actually pull the TCM I found burnt up resistors and capacitors.

IMG_3201.webp


IMG_3202.webp
 
ppc said:
The 93-94 models use a separate transmission control unit and your current symptoms seem to match when I accidentally disconnected in my truck while routing the wiring for some new toys
Click to expand...
TCU, just as I suggested in post #22. Accurate testing and documentation is critical. You failed multiple times in that regard.
 
Glad you found the problem, do you plan to have a shop rebuild the circuit board or just find a replacement?
 
That'll do it. I forgot you had a 2nd gen, but you knew you had a TCM. Good catch.
 
ppc said:
TCU, just as I suggested in post #22. Accurate testing and documentation is critical. You failed multiple times in that regard.
Click to expand...
Hi PPC, I want to absolutely acknowledge you were correct. However, Im not a mechanic and *Whoops* I pulled the left most board, which I guesss was the ECU. (In my defence, I did ask which board to pull) Yes, I took the "hard way" to fix it, But replaced components that were original and prone to fail anyhow. The big "success" that outweigs these failures is 1. I paid 3000 for this truck with a "blown transmisssion" and managed to fix it for under 475$. 2. I was able to actually post the fix and share what caused this problem for me (Seriously thanks to you guys for helping) whereas I've read no less than 4 threads with similar issues where the OP gave up and sent it to a shop. Its a huge win and I learned alot in the process which outweighs my failures as a troubleshooter. :) I now have a nice running rig for 3475$ and will go through more upgrades to give it the TLC it needs. And Malleus PPC and all the other contributors, Thank you personally for all the advice as well.
 
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