M/T - Harsh Shifting

TRANSMISSION & CLUTCH
TC003-03

June 13, 2003

Title:
SMT HARSH SHIFT

Models:
'02 - '03 MR2 Spyder

Introduction

Some owners of 2002 or 2003 model year MR2 Spyder vehicles equipped with Sequential Manual Transmission (SMT) may find the clutch might not disengage completely when downshifting frequently. This condition can result in harsh shifts. A new Transmission Control ECU (SAE Term: Transmission Control Module or TCM) has been introduced to address this owner concern. Follow the repair procedure in this bulletin to correct this condition.

Applicable Vehicles
^ 2002 - 2003 model year MR2 Spyder vehicles with Sequential Manual Transmission produced BEFORE the Production Change Effective VIN shown below.





Production Change Information





Parts Information





Required Tools & Material





Warranty Information

Applicable Warranty *:

This repair is covered under the Toyota Powertrain Warranty. This warranty is in effect for 60 months or 60,000 miles, whichever occurs first, from the vehicle's in-service date.

* Warranty application is limited to correction of a problem based upon a customer's specific complaint.

Repair Procedure

1. Verify the customer complaint.

2. Back the vehicle into the repair stall (this will place the vehicle in a correct position for a later repair step).

3. Verify the shifter is in the "N" position and set the parking brake.





4. Replace the Transmission Control ECU (TCM), located under the panel behind the driver's seat.

5. Replace the Transmission Control ECU (TCM).

A. Record the radio station presets.

B. Turn IG OFF and remove the key from the ignition switch.





C. Disconnect the negative (-) terminal from the battery, or remove the 10A SMT-B fuse from junction block No. 1.

D. Remove the four retaining bolts from the Transmission Control ECU (TCM) mounting flanges before disconnecting the electrical connector of the original (old) ECU.





E. Connect the electrical connector to the replacement (new) Transmission Control ECU (TCM) before securing the ECU with the four retaining bolts.

NOTE:
If the motor pump can be heard running at this step, the "Initial Learning" process for the Transmission Control ECU (TCM) will NOT be successful.

If the pump had run, do the following:

1. Completely disconnect the electrical connector from the TCM.

2. Wait 30 seconds or more, until the pressurized fluid drains.

















3. Repeat Step "A" shown.

HINTS:
^ Perform this operation in a well-lighted area.

^ Visually confirm that the electrical connector attaching hook is first properly engaged under the TCM pin when reconnecting.

^ Swing the wiring harness electrical connector in a single, fluid motion into the TCM connector. SLOW OR UNEVEN ENGAGEMENT OF THE CONNECTORS CAN RESULT IN THE MOTOR PUMP RUNNING.

^ Visually confirm that the connectors are properly aligned, and that the metal arm can fully close easily.

^ Confirm that the connectors are secure, and that no movement occurs between the connector halves when moving the TCM or harness.

F. Reinstall the 10A SMT-B fuse or reconnect the negative (-) terminal to the battery.

6. With the replacement (new) Transmission Control ECU (TCM) installed, perform the following "Initial Learning of Transmission Control ECU After Parts Replacement."

BEFORE BEGINNING:

^ Stop the vehicle.

^ Close the driver side door (the door courtesy light switch provides a ground for the Transmission Control ECU [TCM]).

^ Shift the lever into the "N" position.

^ Verify the ignition switch is OFF.

7. Test drive to verify SMT is shifting normally.