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1996 3.0L Gen 3/KZN185, Potential Autobox Issue

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  • 1996 3.0L Gen 3/KZN185, Potential Autobox Issue

    Hello!

    First time poster, first time owner of a Hilux Surf (own a 3.4 petrol 4Runner back in the states but new to the diesel engine). It's the 1996 KZN185 3.0L Gen 3, with just over 155k miles on it.

    The issue I'm having it is when I'm accelerating from a stop or low speed, particularly noticeable when I need to make a quick acceleration or accelerate up the hill. I seem to have minimal power, revving all the way up to 2500 rpms before I notice a sluggish movement. This is a marked difference from the power I've felt with the acceleration the past few month of owning it. Randomly, the fault rarely occurred over the past few months and especially in conjunction when I would press the O/D button (accompanied by the flashing O/D light). However, it seemed to only happen briefly and then return to normal. Over the past week or two, it occurred a couple times but then seemed to go away. However, when I got the vehicle back from a full service and repair (new suspension, bits and pieces that needed to be done, new fuel and air filers and oil/diff fluid changes) it seems to be happening more than 50% of the time while driving it, especially once it warms up and drives for more than 15-20 minutes. It's again accompanied by the flashing O/D light, my fuel economy has tanked and it seems to not be shifting in other gears until extra high revs. It seems like I don't shift into low gears anymore.

    Took it to the garage to check, the autobox oil was at a perfect level but from the looks of it was very old and viscous. First things first, a full autobox oil change and filter change is needed I assume. Secondly, from my research into this forum it sounds like others have had this issue and may have been solved by replacing the No. 1 autobox solenoid, if it shows the error code 62? Can anyone help me out with this with advice on what might it be or if there is a particular mechanic/specialist in the Cornwall area?

  • #2
    I have the same model, KZN185. I’m getting codes 62 (solenoid 1) and 64 (lock up solenoid) from the O/D Light flashing (jumping the diagnostic terminals). I have replaced all 3 solenoids with matching parts and changed the filter as well as refilled with the ATF from Toyota. I cleared the code and I can drive for about 10-15 mins no light blinking. After that I experience the sluggish accel and flashing O/D.

    Have you made any progress?

    My next replacement part is the computer. After that I’m going to try wiring. I’m at a loss myself but if it’s not the mechanical failure of a solenoid it points to electrical…PLEASE let me know if you have learned anything.

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    • #3
      I know nobody’s responding here but maybe someone will see this and might know. Does the transmission take commands from the ECU or the 4WD computer? Im not getting any continuity from my solenoid plugs at the transmission to any of the pins leading to the 4wd computer.

      Through research I also found some ECUs lose the “overdrive circuit” which is making me think I’m working on the wrong computer. I dug into my passenger side kick panel trim and don’t see any other computers beside the 4WD. That said my second question is, what’s the location of the 3rd Gen engine control computer (ECU)?

      Please if anyone knows the answer to these 2 questions, let me know. I greatly appreciate it.

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      • #4
        Well the trans I believe is operated via the ECU which is behind the passenger footwell kick panel. The 4wd ecu just controls the 4wd system as far as I know.

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        • #5
          ECU is behind glove box. As stated the 4WD ECU is just for 4WD.

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          • #6
            [USER="27"]NiftyNev[/USER] thank you! I am hoping I’ve figured out the issue. I’m going to track down the ECU and test the plug to make sure I have a connection to the solenoid plug by the transmission. If it’s good I’m going to pursue the ECU. Thank you again for the reply!

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            • #7
              A week late but this may be of some help.

              Remove the ECU from behind the glove box. Strip it down and physically check the PCB inside. I recently had to have my rebuilt by "The ECU Doctor" when I discovered that a couple of capacitors had burst burning the copper tracks on the board. This was also giving me trans issues and codes though I forget the trans codes.

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              • #8
                I have the same issue as the OP since a few days now. Nobody seems to have a clue and it is driving me mad. Maybe some new information came up somewhere? Please?

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