TOYOTA A440F,A440L AUTOMATIC TRANSMISSION -REPAIR MANUAL Nov.,1984FOREWORD This repair manual has been prepared to provide information covering general service repairs for the Automatic Transmission with Overdrive, A440F and A440L transmissions. Applicable models: AS40F — FJ62 series FJ70, 73 series, HUGO series Alll information contained in this manual is the most up-to-date at the time of publication. However specifications and pro- cedures are subject to change without notice. TOYOTA MOTOR CORPORATIONTOYOTA AUTOMATIC TRANSMISSION A440F,A440L REPAIR MANUAL INTRODUCTION HX AUTOMATIC TRANSMISSION EM SERVICE SPECIFICATIONS MNS STANDARD BOLT TORQUE SPECIFICATIONS [EE SST AND SSM AUTOMATIC TRANSMISSION HYDRAULIC CIRCUIT [DH 1987 TOYOTA MOTOR CORPORATION srs book may not beInt INTRODUCTION Page HOW TO USE THIS MANUAL + IN2 GENERAL REPAIR INSTRUCTIONS 2 INS INS ABBREVIATIONS USED IN THIS MANUAL ..IN2 INTRODUCTION — How to Use This Manual HOW TO USE THIS MANUAL To assist in finding your way through the manual, the Section Title and major heading are given at the top of every page. An INDEX is provided on the 1st page of each section to guide you to the item to be repaired, At the beginning of each section, PRECAUTIONS are given that, pertain to all repair operations contained in that section. Read these precautions before starting any repair task. REPAIR PROCEDURES Most repair operations begin with an overview illustration. It identifies the components and shows how the parts fit together. Example: Kgem (elo, Nanl] + Specified torque © Non-reusable part I_Precoated part Transmission Housing 69 [b> Neutral Start Switch @ Gasket if sy Bearing oe gagae * esting 0 7) NY ® err MO — @o. Bearing vs See ese aa eT Front Case Subanembiy, 7 Seay & oe (25008 407 aay, o> fee Ne [95 14 19) Rear Case ae [7503.97INTRODUCTION — How to Use This Manual INS Mlustration: what to do and where [Lo ‘The procedures are presented in a step-by-step format: ‘© The illustration shows what to do and where to do it. © The task heading tells whar to do. © The detailed text tells how to perform the task and gives other information such as specifications and warnings. Example: _-—Task heading: what to do 21, CHECK PISTON STROKE OF OVERDRIVE BRAKE (a) Place SST and a dial indicator onto the overdrive brake piston as shown in the figure. SST 09350-30020 (09350-06120) 7 ~\ Set*part No. Compénent part No. Detail text: how to do it (b) Measire the stroke applying and releasing the com pressed air (4 — 8 kg-cm®, 57 — 114 psi or 302 — 785 kPa as shown in the figure. Piston stroke: 1.4 — 1.7 mm (0.055 — 0.067 in.) Specification This format enables the experienced technician to have a FAST TRACK. He can read the task headings and only refer to the detailed text when he needs it. Important specifications and warnings always stand out in bold type. REFERENCES References have been kept to a minimum. However, when they are required you are given the page to go to, SPECIFICATIONS Specifications are presented in bold type throughout the text in ‘the applicable step. You never have to leave the procedure to look up your specs. All specifications are also found in Appen- dix A, specifications for quick reference. WARNINGS, CAUTIONS, NOTES: © WARNINGS are presented in bold type, and indicate there is a possibility of injury to you or other people. @ CAUTIONS are also presented in bold type, and indicate the possibility of damage to the components being repaired. © NOTES are separated from the text but do not appear in bold. They provide additional information to help you efficiently perform the repair.IN4. INTRODUCTION ~ General Repai Instructions GENERAL REPAIR INSTRUCTIONS it Seal Lock Adhesive 10. id: Use fender, seat and floor covers to keep the vehicle clean and prevent damage. During disassembly, keep parts in order to facilitate reas- sembly, Before performing electrical work, disconnect the cable from the battery terminal. Check hose and wiring connectors to make sure that they are secure and correct. Non-reusable Parts (a) Always replace cotter pins, gaskets, O-rings and oil seals etc. with new ones. {b) Non-reusable parts are indicated in the component illustrations by the “@" symbol. Precoated Parts Precoated parts are the bolts, nuts, etc. which are coated with a seal lock adhesive at the factory. (a) If 2 precoated part is retightened, loosened or caused to move in any way, it must be recoated with the specified adhesive {b) Recoating of Precoated Parts (1) Clean off the old adhesive from the bolt, nut or installation part threads. (2) Dry with compressed air. (3) Apply the specified seal lock adhesive to the bolt or nut threads. (c)_ Precoated parts are indicated in the component illust: rations by the “4” symbol. When necessary, use a sealer on gaskets to prevent leaks. Carefully observe all specifications for bolt tightening tor: ques. Always use a torque wrench, Use of special service tools (SST) and special service mate rials (SSM) may be required, depending on the nature of the repair. Be sure to use SST and SSM where specified and follow the proper work procedure. A list of SST and ‘SSM can be found at the back of this manual, When replacing fuses, be sure the new fuse is the correct amperage rating. DO NOT exceed the fuse amp rating or Use one of a lower rating. Care must be taken when jacking up and supporting the vehicle. Be sure to lift and support the vehicle at the pro per locations. {a) If the vehicle is to be jacked up only at the front or rear end, be sure to block the wheels to ensure safety. (b) After the vehicle is jacked up, be sure to support it on stands. It is extremely dangerous to do any work on ‘the vehicle raised on jack alone, even for a small job that can be finished quickly.INTRODUCTION — Abbreviations Used in This Manual INS ABBREVIATIONS USED IN THIS MANUAL ATF Automatic Transmission Fluid Bo Overdrive Brake B: Second Brake Ba First and Reverse Brake Co Overdrive Direct Clutch G Front Clutch Cs Rear Clutch D Disc Ex. Except Fo Overdrive One-way Clutch F, No. 2 One-way Clutch oD Overdrive Pp Plate ssM Special Service Materials ssT Special Service Tools, STD Standard wi With w/o WithoutAUTOMATIC TRANSMISSION Page DISASSEMBLY OF TRANSMISSION (A440F) .. AT.2 DISASSEMBLY OF TRANSMISSION (A440L) .. AT.17 COMPONENT GROUP DISASSEMBLY, INSPECTION AND ASSEMBLY NOTES AT-27 MANUAL VALVE LEVER AND SHAFT AT-28 PARKING LOCK PAWL (A4d0F) AT31 PARKING LOCK PAWL (A440L) AT-34 EXTENSION HOUSING (A440L) AT-36 OIL PUMP ee AT-37 OVERDRIVE PLANETARY GEAR AND OVERDRIVE DIRECT CLUTCH (Co) .. AT-42 OVERDRIVE SUPPORT AT-50 FRONT CLUTCH (ci) AT55 REAR CLUTCH (C2) AT-61 CENTER SUPPORT ............., AT-65 PLANETARY GEAR AND OUTPUT SHAFT (A440F) .... a. AT69 PLANETARY GEAR AND OUTPUT SHAFT (A440L) o.oo... AT-76 FIRST AND REVERSE BRAKE (Bs) AT-82 GOVERNOR VALVE ASSEMBLY ... AT-87 VALVE BODY : AT-92 Disassembly of Valve Body AT-92 Front Upper Valve Body . AT-96 Rear Upper Valve Body . AT-102 Lower Valve Body .. . AT-111 Assembly of Valve Body .. - AT-121 ASSEMBLY OF TRANSMISSION (A440F) AT-125 ASSEMBLY OF TRANSMISSION (A440L) ..... AT-147AT2 AUTOMATIC TRANSMISSION — Disassembly of Transmission (A440F) DISASSEMBLY OF TRANSMISSION (A440F) COMPONENTS Lock Washer [Poon 77) Neutral Start Switen —— Control Shaft Lever aoe VE = TS [650 47. 641 | 8, @ 130 (9, 13) oF C @ORIng Transfer Adapter Spacer Spacer | | Transmission un ernot Bod ees cme La Position Switch oi Pump Torque Converter ne Neutral Position Spesdometer Drive Gear Washer Eront Drive Shit Fork 1 SraH Sibssombiy Bearing seam) = 10 8, Rear Output Shaft Assembly ——— - “ “Teansfor input Gear Power Take-off Drive Gear xf a m 9 OL nw Washer Ider Gear Shaft Bearing Bearing | Thrust Washer re sir (450 (93,44) 5 Lock Prate ree fn pacer ve =e Poring [Ponte Locking Ball — 8 1 ‘Thrust Washer- rx .2 Case Cover Gasket Power Take-off Cover Bearing Retainer )}97 B——S Lock Nut | nal ‘Washer Rear Companion Ta aa Speci torus LS TTA lGonm Fane © Noreremable were Seeders Cen Sar 1 _Precoated partAUTOMATIC TRANSMISSION — Disassembly of Transmission (A440F) AT:3 COMPONENTS (Cont'd) OGasker Front Clutch @0-Ring | Accumulator Cover ‘Ist and Rev. Brake Piston {Ist and Rev. Brake Assembly Planetary Gear |") and Output Shaft Snap Ring an Transmission Rear Cover Gasket © Ist and Rew. Brake r turn Sprin Assembly Spring re ‘Transmission Case ae 4 Accumulator 4 Qo seo Center Support Assembly Rear Clutch ‘Assembly | Front Clutch ‘Assembly ‘ssembly | Tras ang 30 Planeta Thrust Bearing Ring Ges” | Throst Bearing Drain Plug OD Direct Cluteh Assembly @ Non-reusable partAUTOMATIC TRANSMISSION sssembly of Transmi SEPARATE BASIC SUBASSEMBLY 1, REMOVE TORQUE CONVERTER 2. REMOVE OIL FILLER GAUGE AND TUBE 3. REMOVE CONTROL SHAFT LEVER 4, REMOVE NEUTRAL START SWITCH (a) Loosen the lock washer claw and remove the nut. (b) Remove the lock washer and grommet. (c) Remove the two bolts and neutral start switch. 6. REMOVE TRANSFER NEUTRAL SWITCH AND TRANSFER L4 POSITION SWITCH (a) Disconnect the three connectors. (b) Remove the transfer neutral position switch. {c) Remove the transfer L4 position switch.ATS 6. REMOVE TRANSMISSION HOUSING (a) Remove the throttle cable retaining plate. {b) Remove the eight bolts and transmission housing, 7. REMOVE SPEEDOMETER DRIVEN GEAR (a) Remove the lock plate, (b) Remove the speedometer driven gear. (c) Remove the O-ring from the speedometer driven gear. 8. REMOVE POWER TAKE-OFF COVER Remove the six bolts, and remove the power take-off cover and gasket. 9. REMOVE TRANSFER NO. 2 CASE COVER Remove the six bolts and remove the transfer No. 2 case cover and gasket.ATS AUTOMATIC TRANSMISSION 10. 1, 12. isassembly of Transmission (A440F) REMOVE TRANSMISSION OUTPUT SHAFT LOCK NUT (a) Using a hammer and chisel, loosen the stacked part of the nut, (b) Using SST to hold the rear companion flange, remove ‘the transmission output shaft lock nut and washer. SST 09330-00021 REMOVE REAR COMPANION FLANGE (a) Using a hammer and chisel, loosen the stacked part of the nut, (b) Using SST to hold the rear companion flange, remove the companion flange lock nut and washer. SST 09330-00021 (c) Remove the rear companion flange. REMOVE REAR OUTPUT SHAFT BEARING RETAINER Remove the six bolts and remove the rear output shaft bearing retainer and gasket.AUTOMATIC TRANSMISSION ~ Disassembly of Transmission (A440F) ATI 13, REMOVE WASHER, SPEEDOMETER DRIVE GEAR AND SPACER 14, REMOVE IDLER GEAR SHAFT LOCK PLATE 15. REMOVE SHIFT PLUG Remove the shift plug and using a magnetic finger, remove the spring and locking ball. 16. REMOVE TRANSFER REAR CASE (a) Remove the fourteen bolts. (b) Using a plastic hammer, remove the transfer rear case. (c)_ Remove the gasket from the transfer front case. {d) Remove the thrust washer from idler gear shaft.ATS. AUTOMATIC TRANSMISSION — Disassembly of Transmission (A440F) 7. 18. 19, REMOVE REAR OUTPUT SHAFT ASSEMBLY WITH FRONT DRIVE SHIFT FORK SHAFT SUBASSEMBLY REMOVE POWER TAKE-OFF DRIVE GEAR (a) Using SST, remove the transfer input gear bearing. SST 09950-20016 (b) Remove the power take-off gear. (c) Remove the spacer. REMOVE TRANSFER INPUT GEAR (a) Using SST, remove the transfer input gear. SST 09950-20016 {b) Remove the O-ring from transmission output shaft.Al WTOMATIC TRANSMISSION — Disassembly of Transmissi n (AS40F) ATS 20. REMOVE IDLER GEAR, BEARING, SPACER AND IDLER GEAR SHAFT (2) Remove the O-ring from the idler gear shaft, {b) Remove the idler gear with the two bearings and spacer. {c) Remove the two bearings and spacer from the idler gear, {d) Remove the thrust washer from idler gear shaft. 21, REMOVE REAR OUTPUT SHAFT FRONT BEARING RETAINER Remove the rear output shaft front bearing retainer from the transfer front case.AT0 AUTOMATIC TRANSMISSION — Disassembly of Transmission (A440F) 22, 23. 24, REMOVE TRANSFER FRONT CASE (a) Remove the four bolts and using a plastic hammer, remove the transfer front case. (b) Remove the gasket and spacer. REMOVE TRANSMISSION REAR BEARING tallation bolts. (a) Remove the ten transfer adapter (b) Using SST, remove the transfer adapter with trans mission rear bearing. ‘SST 09350-36010 (09350-06140) {c) Remove the gasket. REMOVE GOVERNOR BODY (a) Remove the spacer from the transmission output shaft, (b) Remove the governor body.AUTOMATIC TRANSMISSION — Disassembly of Transmission (A440F) ATU 25. REMOVE OIL PAN {a) Position the oil pan so it does not tilt upright, (b} Remove the twenty bolts and remove the oil pan and gasket. CAUTION: © Do not dent the oil pan. © Do not turn the transmission over, as this will contami- nate the valve body with the foreign materials in the bottom of the pan. 26. EXAMINE PARTICLES IN PAN Remove the magnet and use it to collect any steel chips, Examine the chips and particles in the pan and on the Magnet to anticipate what type of wear you will find in the transmission. Steel (magnetic)...bearing, gear and clutch plate wear Brass (non-magnetic)...bushing wear 27. REMOVE OIL TUBE (a) Remove the lock up relay valve body plate. NOTE: Do not drop the lock up relay valve pins. {b) Pry up both tube ends with the large screwdriver and remove the oil tube. {c)_ Temporarily install the lock up relay valve body plate with four short bolts, 28. REMOVE OIL STRAINER Remove the ten bolts and remove the oil strainer and gasket.AUTOMATIC _TRANSM! isassembly of Transmission (A440F) LON 29, REMOVE VALVE BODY (a) Remove the fifteen bolts. (b) Disconnect the throttle cable from the cam. {c) Remove the valve body from the transmission case. 30. REMOVE FOUR TRANSMISSION CASE APPLICATION GASKETS 31, REMOVE THROTTLE CABLE Using 10-mm socket, push the plastic throttle cable re- tainer, out of the transmission case. 32, REMOVE C: ACCUMULATOR PISTON AND SPRING Applying compressed air to. the oil hole, remove the C2 accumulator piston and spring as shown in the figure.AUTOMATIC TRANSMISSION isassembly of Transmission (A440F) AT-13 33. REMOVE 8, AND B, ACCUMULATOR PISTONS AND 34, 35. SPRINGS Applying compressed air to the oil hole, remove the By and B, accumulator pistons and two springs as shown in the figure, REMOVE C: ACCUMULATOR PISTON AND SPRING {a) Remove the four bolts and remove the front clutch accumulator cover. {b) Remove the plate and two gaskets. {c) Applying compressed air to the oil hole, remove the C: accumulator piston and spring as shown in the figure. REMOVE OIL PUMP (a) Place matchmarks on the oil pump body and trans- mission case. {b) Remove the eleven bolts. {c) Using SST, pull off the oil pump from the transmis- sion case, SST 09350-36010 (09350-06140)AUTOMATIC TRANSMISSION — Disassembly of Tran: 36. 37. 38. 39. sion (A440F) (d) Remove the race and O-ring. MEASURE DISTANCE BETWEEN TOP OF CASE AND CLUTCH DRUM Set SST on the case as shown in the figure. ‘SST 09350-36010 (09350-06090) Make a note of the distance for assembly. REMOVE OVERDRIVE DIRECT CLUTCH AND OVER: DRIVE PLANETARY GEAR Grasp the shaft and pull out the overdrive direct clutch and overdrive planetary gear. Watch for bearings and races on both sides of assembly. REMOVE OVERDRIVE PLANETARY RING GEAR Watch for bearing and races on both sides of assembly. REMOVE OVERDRIVE SUPPORT (a) Using a screwdriver, remove the snap ring.AUTOMATIC TRANSMISSION — Disassembly of Transmission (A440F) AT-5 (b) Remove the three overdrive support lock bolts, {c)__ Using SST, remove the overdrive support, SST 09350-36010 (09350-06140) (d) Remove the three O-rings from the overdrive support. . MEASURE DISTANCE BETWEEN TOP OF CASE AND CLUTCH DRUM Set SST on the case as shown in the figure. SST 09350-36010 (09350-06090) Mark the note of the distance for assembly. 41, REMOVE FRONT CLUTCH ASSEMBLY Remove the front clutch assembly from the rear clutch. Watch for bearing and races on both sides of assembly. 42, REMOVE REAR CLUTCH ASSEMBLY Insert two wire hooks into flukes of the clutch disc and remove the rear clutch assembly.AT-16 AUTOMATIC TRANSMISSION — Disassembly of Transmission (A440F) 43, REMOVE CENTER SUPPORT (a) Remove the three center support lock bolts. {b) Using SST, remove the center support. ‘SST 09350-36010 (09350-06140) (c) Remove the three O-rings from the center support. 44, REMOVE PLANETARY GEAR AND OUTPUT SHAFT (a) Using a screwdriver, remove the snap ring. (b) Remove the planetary gear and output shaft with the ‘one-way clutch. 45, REMOVE TRANSMISSION REAR COVER Remove the three bolts and six screws and remove the transmission rear cover and gasket.AUTOMATIC TRANSMISSION — Disassembly of Transmission (A440L) AT-A7 DISASSEMBLY OF TRANSMISSION (A440L) COMPONENTS (650-107 ai} Transmission Housing Torque Converter rr I Neutral Start Switch °° Oil Filler Gauge: [30 (9.13) Race a po Conot Sat 1 ee ou Pump oi ier Tube oa | nt Viet) 2 ——# oning fe Extention Hosting ca (aaa) $ 0.8% —0 Spendomete Driven Gea Seontancer Snap Ring Spacor Gasket Governor Body [kgem ftib, Nl) + Speciies torque © Non-reusable part aaAT-18 AUTOMATIC TRANSMISSION — Disassembly of Transmission (A440L) COMPONENTS (Cont'd) 1st and Rev. Brake Piston Ast and Rev, Brake Assembly Planetary Gear ‘and Output Shaft Snap Ring Aas and Rev. Brake Return Spring Assembly | Snap Ring Piston Center Support Assembly Rear Clutch 0 Assembly ‘Thrust Bearing Front Clutch ‘Assembly | Assembly Thrust Bearing 0D Planotary | Ring Gear Race OD Direct Clutch Assembly ‘Thrust Bearing kgm (lb, Nani] = Specified torque @ = Non-rousable part sk: Precoated part Te ‘Accumulator Front Clutch ‘Accumulator Cover Gasket | Plate ) Accumulator Piston der Power Take-off Cover ok (3518) & Spring -@ O-Ring SH —o case Dist S——Maanet &— Drain PlugAUTOMATIC TRANSMISSION — Disassembly of Transmis. n (A440) SEPARATE BASIC SUBASSEMBLY 1. REMOVE TORQUE CONVERTER 2. REMOVE OIL FILLER GAUGE AND TUBE 3. REMOVE CONTROL SHAFT LEVER 4. REMOVE NEUTRAL START SWITCH (a) Loosen the lock washer claw and remove the nut. (b) Remove the lock washer and grommet. (c) Remove the two bolts and neutral start switch. 5. REMOVE TRANSMISSION HOUSING {a) Remove the throttle cable retaining plate. {b) Remove the eight bolts and transmission housing, 6. REMOVE SPEEDOMETER DRIVEN GEAR (a) Remove the lock plate (b) Remove the speedometer driven gear. (c)_ Remove the O-ring from the speedometer driven gear.AT-20 [AUTOMATIC TRANSMISSION — Disassembly of Transmission (A440L) 1 9. 10. u. REMOVE EXTENSION HOUSING {a) Remove the ten bolts and extension housing. (b) Remove the gasket. REMOVE SPEEDOMETER DRIVE GEAR AND SPACER REMOVE GOVERNOR BODY REMOVE OIL PAN (a) Position the oil pan so it does not tilt upright. (b) Remove the twenty bolts and remove the oil pan and gasket. CAUTION: * Do not dent the oil pan. ‘* Do not turn the transmission over, as this will contami- nate the valve body with the foreign materials in the bottom of the pan. EXAMINE PARTICLES IN PAN Remove the magnet and use it to collect any steel chips. Examine the chips and particles in the pan and on the magnet to anticipate what type of wear you will find in the transmission Steel (magnetic)...bearing, gear and clutch plate wear Brass (non-magnetic)...bushing wearAUTOMATIC TRANSMISSION ~ Disassembly of Transmission (A440L) AT21 12, REMOVE OIL TUBE (a) Remove the lock up relay valve body plate. NOTE: Do not drop the lock up relay valve pins. {b) Pry up both tube ends with the large screwdriver and remove the oil tube. (c) Temporarily install the lock up relay valve body plate with the four short bolts. 13, REMOVE OIL STRAINER Remove the ten bolts and remove the oil strainer and gasket. 14. REMOVE VALVE BODY (a) Remove the fifteen bolts. {b) Disconnect the throttle cable from the cam. {c) Remove the valve body from the transmission case.AT-22 AUTOMATIC TRANSMISSION — Disassembly of Transmission (A440L) 15, REMOVE FOUR TRANSMISSION CASE APPLICATION GASKETS 16, REMOVE THROTTLE CABLE Using 10:mm socket, push the plastic throttle cable re: tainer, out of the transmission case. 17. REMOVE C;,B, AND B, ACCUMULATOR PISTONS AND SPRINGS (a) Applying compressed air to the oil hole, remove the C2 accumulator piston and spring as shown in the figure. {b) Applying compressed air to the oil hole, remove the B, and B; accumulator pistons and two springs as shown in the figure. 18. REMOVE C: ACCUMULATOR PISTON AND SPRING (a) Remove the four bolts and remove the front clutch accumulator cover. (b) Remove the plate and two gaskets.AUTOMATIC TRANSMISSION 19. 20. isassembly of Transmission (A440L) AT-23 {c) Applying compressed air to the oil hole, remove the 1 accumulator piston and spring as shown in the figure. REMOVE OIL PUMP (a) Place matchmarks on the oil pump body and trans- mission case. {b) Remove the eleven bolts. (c) Using SST, pull off the oil pump from the transmis- sion case. SST 09350-36010 (09350-06140) (d) Remove the race and O-ring. MEASURE DISTANCE BETWEEN TOP OF CASE AND CLUTCH DRUM Set SST on the case as shown in the figure, SST 09350-36010 (09350-06090) Make a note of distance for reassembly.AUTOMATIC TRANSMISSION — Disassembly of Transmission (A440L) 2 REMOVE OVERDRIVE DIRECT CLUTCH AND OVER- DRIVE PLANETARY GEAR Grasp the shaft and pull out the overdrive direct clutch and overdrive planetary gear. Watch for bearings and races on both sides of the assembly, 22, REMOVE OVERDRIVE PLANETARY RING GEAR Watch for bearing and races on both sides of assembly. 23. REMOVE OVERDRIVE SUPPORT {a} Remove the three overdrive support lock bolts. (b) Using SST, remove the overdrive support. SST 09350-36010 (09350-06140) (c) Remove the three O-rings from the overdrive sup: port. 24, MEASURE DISTANCE BETWEEN TOP OF CASE AND CLUTCH DRUM Set SST on the case as shown in the figure. ‘SST 09350-36010 (09350-06090) Mark the note of the distance for assembly.AUTOMATIC TRANSMISSION — Disassembly of Transmission (A440L) 25 25. REMOVE FRONT CLUTCH ASSEMBLY Remove the front clutch assembly from the rear clutch. Watch for bearing and races on both sides of assembly. 26. REMOVE REAR CLUTCH ASSEMBLY Insert two wire hooks into the flukes of the clutch disc and remove. 27. REMOVE CENTER SUPPORT (a) Remove the three center support lock bolts. (b) Using SST, remove the center support. SST 09350-36010 (09350-06140) (c) Remove the three O-rings from the center support. 28. REMOVE PLANETARY GEAR AND OUTPUT SHAFT {a) Using a screwdriver, remove the snap ring.AUTOMATIC TRANSMISSION isassembly of Transmission (A440L) {b) Remove the planetary gear and output shaft with one-way clutch. 29. REMOVE POWER TAKE-OFF COVER Remove the six bolts, and remove the power take-off cover and gasket. 30, REMOVE TRANSMISSION REAR COVER Remove the three bolts and six screws and remove the transmission rear cover and gasket.AUTOMATIC TRANSMISSION — (ee A ee Inspection and Assembly Notes AT27 COMPONENT GROUP DISASSEMBLY, INSPECTION AND ASSEMBLY NOTES: The instructions here are organized so that you work on only one component group at a time. This will help avoid confusion from similar-looking parts of different subassemblies being on your workbench at the same time. The component groups are inspected and repaired from the converter housing side. GENERAL CLEANING NOTES: 1. Al disassembled parts should be washed clean with any fluid passages and holes blown through with compressed air. 2. When using compressed air to dry parts, always aim away from yourself to prevent accidentally spraying automatic transmission fluid or kerosene in your face. PARTS ARRANGEMENT: 1. After cleaning, the parts should be arranged in proper order to allow performing inspection, repairs, and reassembly with efficiency. 2. When disassembling a valve body, be sure to keep each valve together with the correspond ing spring. GENERAL ASSEMBLY: 1. All oil seal rings, clutch discs, clutch plates, rotating parts, and sliding surfaces should be coated with transmission fluid prior to re assembly. 2. All gaskets and rubber O-rings should be re- placed: 3. Make sure that the ends of a snap ring are not, aligned with one of the cutouts and are in- stalled in the groove correctly. ‘As much as possible, complete the inspection, repair and assembly before proceeding to the next component group. If a component group cannot be assembled because parts are being ordered, be sure to keep all parts of that group in a separate container while proceeding with disassembly, in- spection, repair and assembly of other component groups. Recommended ATF type DEXRON® IL The recommended automatic transmission fluid or kerosene should be used for cleaning, 3. New brakes and clutches that are to be used for replacement must be soaked in transmis: sion fluid for at least two hours before assembly, 4. If a worn bushing is to be replaced, the sub: assembly containing that bushing must be replaced. 5. Check thrust bearings and races for wear or damage. Replace if necessary. 6. Use petroleum jelly to keep parts in place.AT-28 AUTOMATIC TRANSMISSION — Manual Valve Lever and Shaft MANUAL VALVE LEVER AND SHAFT —Teansmission | ois @ ~ Manual Valve Shaft @ Parking Lock Rod Manual Valve Lever ©—*orseat J ein} @ _Non-eusable part ox — 1, REMOVE MANUAL VALVE LEVER AND SHAFT (a) Using a screwdriver or chisel, cut off the spacer and remove it from the shaft. {b) Using a punch, drive out the pin.AUTOMATIC TRANSMISSION — Manual Valve Lever and Shaft AT29 \ a 2. (c) Pull the manual valve shaft out through the case by the threads. (d) Disconnect the parking lock rod from the manual valve lever. REMOVE OIL SEAL Using a screwdriver, remove the oil seal. INSTALL NEW OIL SEAL (a) Coat a new oil seal lip with MP grease. (b) Using SST, drive in the oil seal. SST 09350-36010 (09350-08150) INSTALL MANUAL VALVE LEVER AND SHAFT (a) Assemble a new spacer to the manual valve lever. (b) Connect the parking lock rod to the manual valve lever.AT-30 AUTOMATIC TRANSMISSION — Manual Valve Lever and Shaft (c) Install the manual valve shaft and wave washer to the transmission case through the manual valve lever by the thread. (d) Drive in the pin with slot at a right angle to the shaft. {e) Match the spacer hole to the lever calking hollow and. calk the spacer to the lever. (f) Make sure the manual valve shaft turns smoothly.AUTOMATIC TRANSMISSION — Parking Lock Pawl (A440F) AT-31 PARKING LOCK PAWL (A440F) ea, rating Lok Pet fae Torsion Spring ea nem Fe Tas) 50 Ring Bracket— ‘Transfer Adapter [Keser ftib, Nem] = Specified torque cane DISASSEMBLY OF PARKING LOCK PAWL 1. REMOVE PARKING LOCK PAWL SHAFT Remove the pawl shaft, torsion spring and plate washers from the transfer adapter. 2. REMOVE SNAP RING FROM PAWL SHAFT WITH SNAP RING PLIERS 3. REMOVE PARKING LOCK PAWL FROM TRANSFER ADAPTERAUTOMATIC TRANSMISSION — Parking Lock Paw! (A440F) 4, REMOVE BRACKET ASSEMBLY OF PARKING LOCK PAWL 1. 3. INSTALL BRACKET TO TRANSFER ADAPTER (a) Temporarily install the bracket with the two bolts. (b) Using SST and calipers, set the bracket so the dis- tance between the transfer adapter surface and the top of the bracket tab is the standard distance. Total distance — SST thickness = STD distance STD distance: 47.5 — 47.6 mm (1.870 — 1.874 in.) SST 09350-36010 (09350-06090) (c)_ Tighten the two bolts. Torque: 195 kg-cm (14 ft-lb, 19 N-m) INSTALL PARKING LOCK PAWL INSTALL SNAP RING TO PAWL SHAFTAUTOMATIC TRANSMISSION — Parl 4. Lock Pawl (A440F) AT-33 INSTALL PARKING LOCK PAWL SHAFT (a) Install the two plate washers and torsion spring to the pawl shaft, (b) Insert the spring end to the hole and install the paw! shaft. {c) Hold the pawl shaft, hook another spring end to the parking lock pawl with a screwdriver. (d) Make sure the parking lock pawl moves smoothly.AT-34 AUTOMATIC TRANSMISSION — Parking Lock Pawl (A440L) PARKING LOCK PAWL (A440L) Extension Housing, Torsion Spring —Parking Lock Paw! Plate Washer — Parking Lock Paw! Shaft kg-cm (ft-lb, Nem)] : Specified torque ——]_ DISASSEMBLY OF PARKING LOCK PAWL 1. REMOVE PARKING LOCK PAWL SHAFT 2. REMOVE PARKING LOCK PAWL, TORSION SPRING AND PLATE WASHER 3. REMOVE BRACKETAUTOMATIC TRANSMISSION — Parking Lock Paw! (A440L) AT-35 ASSEMBLY OF PARKING LOCK PAWL 1. INSTALL BRACKET TO EXTENSION HOUSING (a) Temporarily install the bracket with the two bolts. (b) Using SST and calipers, set the bracket so the dis tance between the extension housing surface and the top of the bracket tab is the standard distance. Total distance — SST thickness = STD distance STD distance: 47.5 — 47.6 mm (1.870 — 1.874 in.) SST 09350-36010 (09350-06090) (c)_ Tighten the two bolts. Torque: 195 kg-cm (14 ft-lb, 19 Nem) ——] 2. INSTALL PARKING LOCK PAWL. (a) Insert the torsion spring end to the hole of the ex: tension housing (b) Install the parking lock pawl, shaft and plate washer. (c) Hook another spring end to the parking lock pawl. (d) Make sure the parking lock pawl moves smoothly.AT-36 AUTOMATIC TRANSMISSION — Extension Housing (A440L) ssT. EXTENSION HOUSING (A440L) 1 REMOVE OIL SEAL WITH SCREWDRIVER REMOVE SNAP RING WITH SCREWDRIVER REMOVE OUTPUT SHAFT REAR BEARING Using SST, press out the bearing from the extension housing, SST 09360-36010 (09350-06050, 09350-06070) INSTALL OUTPUT SHAFT REAR BEARING Using SST, press the bearing into the extension housing. SST 09350-36010 (09350-06050, 09350-06080) INSTALL SNAP RING NOTE: Be sure the end gap of the snap ring is not aligned with one of the cutouts. INSTALL NEW OIL SEAL (a) Coat a new oil seal lip with MP grease. (b) Using SST, drive in the oil seal. The oil seal end should be flush with the outer edge of the extension housing, SST 09350-36010 (09350-06040)AUTOMATIC TRANSMISSION — Oi! Pump AT-37 OIL PUMP il Pump Drive Gear O-Ring =) Sh, Qo oir seal Ring \ Oil Seal ° Spring Spring Seat il Pump Cover Oil Pump Driven Gear Check Ball il Pump Body @ _Non-eusable part oat 1, USE TORQUE CONVERTER AS WORK STAND 2. REMOVE O-RING 3. REMOVE TWO OIL SEAL RINGSAUTOMATIC TRANSMISSION — Oil Pump. 4. REMOVE CHECK BALL (a) Using SST, compress the spring and remove the spring seat. SST 09360-36010 (09350-06100) (b) Remove the spring and check ball. REMOVE OIL PUMP COVER Remove the eight bolts, and then remove the oil pump cover from the oil pump body. REMOVE OIL PUMP DRIVE GEAR AND DRIVEN GEAR INSPECTION OF OIL PUMP 1 USE TORQUE CONVERTER AS WORK STAND Place the torque converter and then place a wooden block, etc., on it. CHECK BODY CLEARANCE OF DRIVEN GEAR Push the driven gear to one side of the body. Using feeler gauge, measure the clearance. Standard body clearance: 0.07 — 0.15 mm (0.0028 — 0.0059 in.) Maximum body clearance: 0.3 mm (0.012 in.) If the body clearance is greater than the maximum, replace the drive gear, driven gear or pump body. CHECK TIP CLEARANCE OF BOTH GEARS Measure between the gear teeth and the cresentshaped part of the pump body. Standard tip clearance: 0.14 — 0.24 mm (0.0055 — 0.0094 in.) Maximum tip clearance: 0.3 mm (0.012 in.) If the tip clearance is greater than the maximum, replace the drive gear, driven gear or pump body.AUTOMATIC TRANSMISSION — Oil Pump AT-39 4. CHECK SIDE CLEARANCE OF BOTH GEARS Using a steel straightedge and a feeler gauge, measure the side clearance of both gears. Standard side clearance: 0.02 — 0.05 mm {0.0008 — 0.0020 in.) Maximum side clearance: 0.1 mm (0,004 in.) If the side clearance is greater than the maximum, replace the drive gear, driven gear or pump body. There are two different thicknesses for drive and driven gears, Drive and driven gear thickness: 18.435 — 18.450 mm (0.7258 — 0.7264 in.) 18.451 — 18.486 mm (0.7264 — 0.7278 in.) CHECK OIL PUMP BODY BUSHING Using a dial indicator, measure the inside diameter of the oil pump body bushing. Maximum inside diameter: 42.13 mm (1.6587 in.) If the inside diameter is greater than the maximum, replace the oil pump body. CHECK OIL PUMP COVER BUSHING Using a dial indicator, measure the inside diameter, of the oil pump cover bushing Maximum inside diameter: Front side 24.07 mm (0.9476 in.) Rear side 26.57 mm_ (1.0461 in.) CHECK OIL SEAL Check for wear, damage or cracks. IF NECESSARY, REPLACE OIL SEAL {a) Pry off the oil seal with a screwdriver. (b) Using SST, install a new oil seal. The oil seal end should be flush with the outer edge of the pump body. ‘SST 09350-36010 (09350-06040) {c) Coat the oil seal lip with MP grease.AT-40 AUTOMATIC TRANSMISSION — Oil Pump. 1. ASSEMBLY OF OIL PUMP: INSTALL OIL PUMP DRIVEN GEAR AND DRIVE GEAR (a) Place the oil pump body on the torque converter. (b) Coat the both gears with ATF. (c) Install the driven gear and drive gear. INSTALL OIL PUMP COVER {a) Align the oil pump cover with the bolt holes and hand tighten the eight bolts. (b)_ Tighten the eight bolts. Torque: 6mm _90 kg-em (78 in.-Ib, 8.8 N-m) 8mm 210 kg-cm (15 ft-lb, 21 N-m) INSTALL CHECK BALL (a) Install the check ball and spring. (b) Using SST, compress the spring and install the spring seat. SST 09350-36010 (09350-06100) INSTALL TWO OIL SEAL RINGS Coat the two oil seal rings with ATF and install. CAUTION: Do not spread the ring ends more than necessary. NOTE: After installing the oil seal rings, check that they move smoothly.AUTOMATIC TRANSMISSION — Oil Pump. AT-A1 5. INSTALL O-RING Coat new O-ring with ATF and install it to the oil pump body. — 6. CHECK OIL PUMP DRIVE GEAR ROTATION Make sure the drive gear rotates smoothly when installed to the torque converter.AUTOMATIC TRANSMISSION ~ Overdrive Direct Clutch (Co)_ AT-42 OVERDRIVE PLANETARY GEAR AND OVERDRIVE DIRECT CLUTCH (Co) “fj | Spring Seat GO-Rins | | Snap Ring ee 08 Planetary Gear Race Ring Gear Flange @ _Non-reussbie part | one-way Clutch Outer Race Nos Thrust Washer DISASSEMBLY OF OVERDRIVE PLANETARY GEAR AND OVERDRIVE DIRECT CLUTCH 1, CHECK OPERATION OF ONE-WAY CLUTCH Hold the OD direct clutch drum and turn the input shaft. The input shaft should turn freely clockwise and should lock counterclockwise, 2. REMOVE OVERDRIVE DIRECT CLUTCH ASSEMBLY FROM OVERDRIVE PLANETARY GEARAUTOMATIC TRANSMISSION — Overdrive Direct Clutch (Co) | 3. ‘drive Direct Clutch (Co) AT-43 REMOVE BEARING AND RACE FROM OVERDRIVE DIRECT CLUTCH CHECK PISTON STROKE OF OVERDRIVE DIRECT CLUTCH (Co) (a) Place the oil pump onto the torque converter. Then place the OD direct clutch onto the oil pump. {b) Using SST and a dial indicator, measure the OD direct clutch piston stroke, applying and releasing the com- pressed air (4-8 kg/em®, 57-114 psi or 392-785, kPa) as shown. SST 09350-36010 (09350-06110) Piston stroke: 1.10 — 1.70 mm (0.0433 — 0.0669 in.) If the stroke exceeds the limit, replace the discs and re- check the piston stroke. If the stroke is less than the limit, parts may be improperly assembled and require reassembly. REMOVE SNAP RING FROM OVERDRIVE DIRECT CLUTCH DRUM REMOVE FLANGE, DISCS AND PLATES COMPRESS PISTON RETURN SPRINGS AND REMOVE SNAP RING Place SST on the spring seat and compress the return spring with a shop press. Using snap ring pliers, remove the snap ring, SST 09350-36010 (09350-06010) REMOVE SPRING SEAT AND TWENTY-FOUR, RETURN SPRINGSAT-44 9. 10. at 12, AUTOMATIC TRANSMISSION — Overdrive Direct Clutch (Co) REMOVE OVERDRIVE DIRECT CLUTCH PISTON (a) Place the oil pump onto the torque converter. ‘Then place the OD direct clutch onto the oil pump. (b) Holding the OD direct clutch piston by hand, apply ‘compressed air to the oil pump to remove the OD direct clutch piston. {c) Remove the OD direct clutch piston. REMOVE TWO O-RINGS FROM PISTON REMOVE ONE-WAY CLUTCH (a) Remove the snap ring with a screwdriver. (b) Remove the No. 4 thrust washer. {c) Remove the one-way clutch with outer race from the planetary gear. (d) Remove the No. 3 thrust washer. {e) Remove the one-way clutch from the one-way clutch outer race. REMOVE OIL SEAL RING FROM RING GEAR FLANGE_ Overdrive Direct Clutch (Co) ATAS 13. REMOVE SNAP RING AND RING GEAR FLANGE (a) Remove the snap ring with a screwdriver (b) Remove the ring gear flange. INSPECTION OF OVERDRIVE PLANETARY GEAR AND OVERDRIVE DIRECT CLUTCH 1. CHECK DISCS Using a micrometer, measure the thickness of the discs. Minimum thickness: 1.9 mm (0.075 in.) If the thickness is less than the minimum, replace the disc. CHECK PISTON RETURN SPRINGS Using calipers, measure the free length of the return springs. Standard length: 21.0 mm (0.827 in.) 3. CHECK OVERDRIVE DIRECT CLUTCH PISTON (a) Check that check ball is free by shaking the piston. (b) Check that the valve does not leak by applying low- pressure compressed 4. CHECK OVERDRIVE DIRECT CLUTCH DRUM BUSHING Using a dial indicator, measure the inside diameter of the clutch drum bushings. Maximum inside diameter: 26.57 mm (1.0461 in.) If the inside diameter is greater than the maximum, replace the clutch drumAT-46 AUTOMATIC TRANSIS ~__Overdrive Direct Clutch (Co) 5. CHECK OVERDRIVE PLANETARY GEAR BUSHING Using a dial indicator, measure the inside diameter of the planetary gear bushing Maximum inside diameter: 12.07 mm (0.4752 in.) If the inside diameter is greater than the maximum, replace the planetary gear. ASSEMBLY OF OVERDRIVE PLANETARY GEAR AND OVERDRIVE DIRECT CLUTCH 1. INSTALL RING GEAR FLANGE (a) Install the ring gear flange to the ring gear. (b) Install the snap ring to the ring gear. INSTALL OIL SEAL RING Coat the oil seal ring with ATF and install it to the ring gear flange. CAUTION: Do not spread the ring ends more than necessary. NOTE: After installing the oil seal ring, check that it moves smoothly. INSTALL ONE-WAY CLUTCH (a) Install the No. 3 thrust washer to the planetary gear, facing the grooved side upward, (b) Install the one-way clutch into the outer race, facing the flanged side of the one-way clutch upward.eevee ene Ee 7 Overdrive Direct Clutch (Co) _ ATA? = (c) Install the assembled one-way clutch and outer race Flanged Side to the planetary gear. {d) Install the No. 4 thrust washer to the planetary gear. {e) Install the snap ring to the planetary gear. —— 4. INSTALL NEW O-RINGS ON OVERDRIVE DIRECT CLUTCH PISTON Coat new O-rings with ATF and install them on the OD direct clutch piston. 5. INSTALL OVERDRIVE DIRECT CLUTCH PISTON TO OVERDRIVE DIRECT CLUTCH DRUM Being careful not to damage the O-rings, press the direct clutch piston into the clutch drum with both hands. _____us] 6, INSTALL TWENTY-FOUR PISTON RETURN SPRINGS AND SPRING SEAT 7. COMPRESS PISTON RETURN SPRINGS AND INSTALL SNAP RING IN GROOVE (a) Place SST on the spring seat and compress the return springs with a shop press. ‘SST 09350-36010 (09350-06010) (b) Install the snap ring. Be sure the end gap of the snap ring is not aligned with the spring seat claw. 8. INSTALL PLATES, DISCS AND FLANGE (a) Install in order: P-D-P—D—P-D (b) Install the flange, facing the rounded edge downward Rounded EdgeAT-48 —— AUTOMATIC TRANSMISSION — Overdri or ( 10. u 12, Direct Clutch (Co)_ INSTALL SNAP RING NOTE: Be sure the end gap of the snap ring is not aligned the cutout portion of the clutch drum. CHECK PISTON STROKE OF OVERDRIVE DIRECT CLUTCH (Co) (a) Place the oil pump onto the torque converter, and then place the OD direct clutch assembly onto the oil pump, (b) Using SST and a dial indicator, measure the OD direct clutch piston stroke, applying and releasing the com- pressed air (4-8 kg/em?, 57-114 psi or 392-785 kPa) as shown. SST 09350-36010 (09350-06110) Piston stroke: 1.10 — 1.70 mm (0.0433 -0.0669 in.) If the stroke exceeds the limit, replace the discs and re- check the piston stroke. If the stroke is less than the limit, parts may be improperly assembled and require reassembly. INSTALL RACE AND BEARING Coat the race and bearing with petroleum jelly and install ‘them onto the OD direct clutch. NOTE: Race and bearing diameter mm (in.) inside Outside Race 28.5 (1.122) 48.0 (1.890) Beering | 28.5 (1.122) 462 (1.819) INSTALL OVERDRIVE DIRECT CLUTCH While pulling and turning the input shaft clockwise install the OD direct clutch assembly to the OD planetary gear.Owardriva Dirant Cree (eo AMTOMATIC TRANSMISSION ~ Overdrive Direct Clutch (Co) AT.49 13. CHECK OPERATION OF ONE-WAY CLUTCH Hold the OD direct clutch drum and turn the input shaft. The input shaft should freely turn clockwise and lock counterclockwiseAT-50 AUTOMATIC TRANSMISSION — Overdrive Support OVERDRIVE SUPPORT r Bearing Snap Ring @ Non-reusable part Ik Precoated part Race id O-Ring OD Brake Piston DISASSEMBLY OF OVERDRIVE SUPPORT 1. CHECK PISTON STROKE OF OVERDRIVE BRAKE (Bs) {a) Place the OD case onto the front clutch. (b) Using SST and a dial indicator, measure the OD brake piston stroke, applying and releasing the compressed air (4-8 kg/em*, 57-114 psi or 392-785 kPa) as shown SST 09350-36010 (09350-06120) Piston stroke: 1.25 — 1.85 mm (0.0492 — 0.0728 in.) If the piston stroke exceeds the limit, replace the discs and recheck the piston stroke.AUTOMATIC TRANSMISSIOT ive Support ATS1 3. REMOVE SNAP RING, FLANGE, DISCS AND PLATES (a) Remove the snap ring with a screwdriver. (b) Remove the flange, dises and plates REMOVE BEARING AND RACE COMPRESS PISTON RETURN SPRING AND REMOVE SNAP RING (a) Place SST on the spring retainer, and compress the return spring with a shop press. SST 09350-36010 (09350-06020) (b) Remove the snap ring with a screwdriver. REMOVE OVERDRIVE BRAKE PISTON (a) Place the matchmarks on the OD brake piston and OD case. (b) Place the return spring on the OD brake piston and then place SST on the return spring. (c) Hold SST so it is not slanted and apply compressed air into the passage to remove the OD brake piston. SST 09350-36010 (09350-06020) (d) Remove the OD brake piston.AT52 AUTOMATIC TRANSMISSION — Overdrive Support — 6, REMOVE TWO OIL SEAL RINGS 7. REMOVE THREE O-RINGS FROM OVERDRIVE CASE INSPECTION OF OVERDRIVE SUPPORT 1. CHECK DISCS Using @ micrometer, measure the thickness of the discs. Minimum thickness: 1.9 mm (0.075 in.) If the thickness is less than the minimum, replace the disc. ————_—————} 2. CHECK PISTON RETURN SPRING Using calipers, measure the free length of the return spring, Standard length: 22.75 mm (0.8957 in.) [Spring Retainer ASSEMBLY OF OVERDRIVE SUPPORT 1. INSTALL TWO OIL SEAL RINGS Coat the oil seal rings with ATF, contract them and install ‘them onto the OD case. CAUTION: Do not spread the ring ends too much. NOTE: After installing the oil seal rings, check that they move smoothly. 2. INSTALL THREE NEW O-RINGS TO OVERDRIVE CASE Coat new O-rings with ATF and install them to the OD case. 3. INSTALL NEW O-RINGS ON OVERDRIVE BRAKE PISTON Coat new O-tings with ATF and install them on the OD brake piston. 4. INSTALL OVERDRIVE BRAKE PISTON (a) Align the matchmarks on the piston and OD case. (b) Being careful not to damage the O-rings, press in the brake piston into the OD case with both hands.AUTOMATIC TRANSMISSION — Overdrive Support AT53 5. INSTALL PISTON RETURN SPRING 6. COMPRESS PISTON RETURN SPRING AND INSTALL SNAP RING IN GROOVE (a) Place SST on the spring retainer, and compress the return spring with a shop press. SST 09350-36010 (09350-06020) (b) Install the snap ring with a screwdriver. Be sure the end gap of the snap ring is not aligned with the cut- out portion of the OD case. 7, INSTALL RACE AND BEARING Coat the race and bearing with petroleum jelly and install them onto the OD case. NOTE: Race and bearing diameter mm (in.) - Inside Outside Race 37.0_(1.487) 520 (2,047) Bearing 34.7_(1.366) 52.0 (2.047) —) 8. INSTALL PLATES, DISCS AND FLANGE (a) Install in order: P-D—P-D-P—D (b) Install the flange, facing the rounded edge downward. Dise— Rounded Edge INSTALL SNAP RING NOTE: Be sure the end gap of the snap ring isnot aligned the cutout portion of the OD case. |. CHECK PISTON STROKE OF OVERDRIVE BRAKE (Bo) (a) Place the OD case onto the front clutch.AT54 AUTOMATIC TRANSMISSION — Overdrive Support {b) Using SST and a dial indicator, measure the OD brake piston stroke, applying and releasing the compressed air (4-8 kg/om?, 57-114 psi or 392-785 kPa) as shown, ‘SST 09350-36010 (09350-06120) Piston stroke: 1.25 — 1.85 mm (0.0492 — 0.0728 in.) If the piston stroke exceeds the limit, replace the discs and recheck the piston stroke. If the stroke is less than the limit, parts may be improperly assembled and require reassembly.AUTOMATIC TRANSMISSION — Front Clutch (C1) AT-55 FRONT CLUTCH (C1) Plate Piston Return Spring 1 Front Clutch | Spring Seat Piston a HP® Snap Ring Dise it Seal Ring Cushion Plate Plate Front Cluteh Drum Race Bearing y t Race Rear Clutch Hub Front Clutch Hub @ Non-reusable part ou DISASSEMBLY OF FRONT CLUTCH 1, PLACE FRONT CLUTCH ASSEMBLY ONTO OVER- DRIVE CASE 2. REMOVE REAR CLUTCH HUB (2) Remove the snap ring with a screwdriver. (b) Remove the rear clutch hub from the front clutch drum.AT56 AUTOMATIC TRANSMISSIOI Front Clutch (C1) REMOVE BEARING AND RACE REMOVE FRONT CLUTCH HUB FROM FRONT CLUTCH DRUM REMOVE RACES AND BEARING FROM FRONT CLUTCH DRUM CHECK PISTON STROKE OF FRONT CLUTCH (Ci) (a) Lift up the rear clutch hub and place the assembled SST and dial indicator. ‘SST 09350-36010 (09350-06110) (b) Install the rear clutch hub and snap ring. (c) Using SST and @ dial indicator, measure the front clutch piston stroke, applying and releasing the com- pressed air (4-8 kg/cm’, 57-114 psi or 392-785 kPa) as shown. ‘SST 09360-36010 (09350-06110) Piston stroke: 3.93 — 4.23 mm (0.1547 — 0.1665 in.) If the piston stroke exceeds the limit, replace the discs and recheck the piston stroke.AUTOMATIC TRANSMISSION — Front Clutch (C:) AT-57 ssT 10. 1. 12. If the piston stroke is nonstandard, select another plate. NOTE: There are four plates. mmm (in) Thickness 18 (0.071) I 2.2 (0.0866) 2.0 (0.078) 24 (0.0946) REMOVE REAR CLUTCH HUB, DISCS, PLATES AND CUSHION PLATE (2) Remove the snap ring with a screwdriver. (b) Remove the rear clutch hub, discs and plates. (c) Remove the cushion plate. COMPRESS PISTON RETURN SPRINGS AND REMOVE SNAP RING (a) Place SST on the spring seat, and compress the return springs with a shop press. SST 09350-36010 (09350-06010) (b) Remove the snap ring with snap ring pliers. REMOVE SPRING SEAT AND TWENTY-TWO RETURN SPRINGS REMOVE FRONT CLUTCH PISTON (a) Holding the front clutch piston so it is not slanted, apply compressed air into the passage to remove the front clutch piston (b) Remove the front clutch piston. REMOVE O-RINGS FROM FRONT CLUTCH PISTON REMOVE OIL SEAL RING WITH SCREWDRIVERAT58 AUTOMATIC TRANSMISSION — Front Clutch (C1) INSPECTION OF FRONT CLUTCH 1. CHECK DISCS Using a micrometer, measure the thickness of the discs. Minimum thickness: 1.9 mm (0.075 in.) If the thickness is less than the minimum, replace the disc. 2. CHECK PISTON RETURN SPRINGS Using calipers, measure the free length of the return springs. Standard length: 30.5 mm (1.201 in.) 3. CHECK FRONT CLUTCH PISTON (a) Check that check ball is free by shaking the piston. (b) Check that the valve does not leak by applying low- pressure compressed air. ASSEMBLY OF FRONT CLUTCH 1, INSTALL OIL SEAL RING (a) Coat the oil seal ring with ATF (b) Contract the oil seal ring and install it to the input shaft. NOTE: After installing the oil seal ring, check that it moves smoothly. 2. INSTALL TWO NEW O-RINGS ON FRONT CLUTCH PISTON Coat new O-rings with ATF and install them on the front clutch piston. 3. INSTALL FRONT CLUTCH PISTON Being careful not to damage the O-rings, press in the clutch piston into the front clutch drum by both hands.AUTOMATIC TRANSMISSION — Front Clutch (Ci) AT59 Spring Seat Claw] 4. INSTALL TWENTY-TWO PISTON RETURN SPRINGS AND SPRING SEAT 5, COMPRESS PISTON RETURN SPRINGS AND INSTALL SNAP RING IN GROOVE (a) Place SST on the spring seat, and compress the return springs with a shop press. SST 09350-36010 (09350-06010) (b) Install the snap ring by hand. Be sure the end gap of the snap ring is not aligned with the spring seat claw. 6. INSTALL CUSHION PLATE Install the cushion plate rounded end down. 7. INSTALL PLATES AND DISCS Install in order: @-D—P—D—P—D-P—D-P-D-P-D 8. CHECK PISTON STROKE OF FRONT CLUTCH (C:) (a) Lift up the rear clutch hub and position the assem bled SST and dial indicator. SST 09350-36010 (09350-06110) (b) Install the rear clutch hub and snap ring. (c)_ Using SST and a dial indicator, measure the front clutch piston strokes, applying and releasing the com- pressed air (4-8 kg/cm?, 57-114 psi or 392-785 kPa) as shown SST 09350-36010 (09350-06110) Piston stroke: 3.93 — 4.23 mm (0.1547 — 0.1665 in.) If the piston stroke exceeds the limit, replace the disos and recheck the piston stroke.Al UTOMATIC_ TRANSMISSION — Front Clutch (C1) 10. nn. 12. If the piston stroke is nonstandard, select another plate. NOTE: There are four plates. rm (in Thickness 18 (0071) 22 (0.0866) 2.0 (0.079) 24 (0.0945) (d) Remove the snap ring and rear clutch hub. INSTALL RACES AND BEARING Coat the races and beating with petroleum jelly and install them onto the front clutch drum. NOTE: Races and bearing diameter. ram (ine) C Inside Outside Race (A) 328 (1.291) 50.4 (1.984) Bearing 34.7 (1.366) 52.0 (2.047) Race (8) 37.0 _(1.487) 520 (2.047) INSTALL FRONT CLUTCH HUB INSTALL RACE AND BEARING Coat the race and bearing with petroleum jelly and install them onto the front clutch hub. NOTE: Race and bearing diameter. mm (in) Inside Outside Race 328 (1.201) 50.4 (1.984) Bearing 347_(1.366) 52.0 (2.047) INSTALL REAR CLUTCH HUB (a) Install the rear clutch hub onto the front clutch drum. {b) Install the snap ring with a screwdriver.AUTOMATIC TRANSMISSION — Rear Clutch (Cz) AT61 REAR CLUTCH (C2) Dise Flange ‘Snap Ring Snap Ring Sa p ZF | Rece Piston Return Fear Clusch Drum | Spring PO-RIng Spring Seat Rear Clutch Piston DISASSEMBLY OF REAR CLUTCH 1, CHECK PISTON STROKE OF FRONT CLUTCH (C1) (a) Place rear clutch drum into the center support. (b) Using SST and a dial indicator, measure the rear clutch piston stroke, applying and releasing the com- pressed air (4-8 kg/em?, 57-114 psi or 392-785 kPa) as shown. SST 09350-36010 (09350-06110) Piston stroke: 1.70 — 1.90 mm (0.0669 — 0.0748 in.) If the piston stroke exceeds the limit, replace the discs and recheck the piston stroke.AT-62 AUTOMATIC TRANSMISSION — Rear Clutch (C:) If the piston stroke is nonstandard, select another flange, NOTE: There are four flanges. mm (in) No. Thickness | No. Thickness | None] 5:0 (0.197) 2 64 (0.213) 1 [52 (0.205) 3 5.6 (0.220) r =e ———>———_ 2. REMOVE FLANGE, DISCS AND PLATES { (a) Remove the snap ring with a screwdriver. 4 7 (b) Remove the flange, dises and plates. 3. COMPRESS PISTON RETURN SPRINGS AND REMOVE SNAP RING (a) Place SST on the spring seat and compress the return springs with a shop press. SST 09350-36010 (09350-06010) (b) Remove the snap ring with snap ring pliers. 4. REMOVE SPRING SEAT AND TWENTY-TWO PISTON RETURN SPRINGS 5. REMOVE REAR CLUTCH PISTON (a) Place the rear clutch drum into the center support. (b) Apply compressed air into the passage to remove the rear clutch piston as shown. {c}_ Remove the rear clutch piston. 6. REMOVE O-RINGS FROM REAR CLUTCH PISTON INSPECTION OF REAR CLUTCH 1, CHECK DISCS Using a micrometer, measure the thickness of the discs. Minimum thickness: 1.9 mm (0.075 in.) If the thickness is less than the minimum, replace the discAUTOMATIC TRANSMISSION — Rear Clutch (C2) AT-63 a 1 ‘Snap Ring Spring Seat Claw 2. CHECK PISTON RETURN SPRINGS Using calipers, measure the free length of the return springs. Standard length: 31.24 mm (1.2299 in.) 3. CHECK REAR CLUTCH PISTON (a) Check that check ball is free by shaking the piston. (b) Check that the valve does not leak by applying low- pressure compressed air to the hole. ASSEMBLY OF REAR CLUTCH 1, INSTALL NEW O-RINGS ON REAR CLUTCH PISTON Coat new O-rings with ATF and install them on the rear clutch piston. 2. INSTALL REAR CLUTCH PISTON Being careful not to damage the O-rings, press in the clutch piston into the rear clutch drum. 3, INSTALL TWENTY-TWO PISTON RETURN SPRINGS AND SPRING SEAT 4, COMPRESS PISTON RETURN SPRINGS AND INSTALL SNAP RING IN GROOVE (a) Place SST on the spring seat, and compress the return springs with a shop press. SST 09350-36010 (09350-06010) (b) Install the snap ring by hand. Be sure the end gap of ‘the snap ring is not aligned with the spring seat claw,AT-64 AUTOMATIC TRANSMISSION 5. ear Clutch (C2) INSTALL PLATES, DISCS AND FLANGE {a) Install in order: P-D—P—D—P—D—P—D—P—D (b) Install the flange facing the rounded edge downward. INSTALL SNAP RING NOTE: Be sure the end gap of the snap ring is not aligned with the cutout portion of the rear clutch drum, CHECK PISTON STROKE OF REAR CLUTCH (C:) (a) Place the rear clutch drum assembly into the center support assembly. (b) Using SST and a dial indicator, measure the rear clutch piston stroke, applying and releasing the com- pressed air (4-8 kg/em?, 57-114 psi or 392-785 kPa) as shown. ‘SST 09350-36010 (09350-06110) Piston stroke: 1.70 — 1.90 mm (0.0669 — 0.0748 in.) If the piston stroke exceeds the limit, replace the discs and recheck the piston stroke. If the piston stroke is less than the limit, parts may be improperly installed and should be reassembled. If the piston stroke is nonstandard, select another flange. NOTE: There are four flanges. mm fin.) [No [Thess [Now [Then None] 6.0 (0.197) 2 84 (0213) | 1 [82 e205) | 3a | 86 (220)AUTOMATIC TRANSMISSION — Center Support AT-65 CENTER SUPPORT Snap Ring Planetary Sun Gear Snap Ring Snap Ring a 1 —~ Thrust Washer ‘Oil Seal Ring | 2nd Brake Piston Piston Return Spring @ _Non-reusable part DISASSEMBLY OF CENTER SUPPORT 1, REMOVE PLANETARY SUN GEAR (a) Remove the snap ring with snap ring pliers. (b) Remove the planetary sun gear. CHECK PISTON STROKE OF SECOND BRAKE (B:) Using SST and a dial indicator, measure the 2nd brake piston stroke, applying and releasing the compressed air (4-8 kg/em?, 57-114 psi or 392-785 kPa) as shown. ‘SST 09350-36010 (09350-06120) Piston stroke: 1.60 — 1.80 mm (0.0630 — 0.0709 in.) If the piston stroke exceeds the limit, replace the discs and recheck the piston stroke.AT-66 AUTOMATIC TRANSMISSION — Center Support {f the piston stroke is nonstandard, select another flange, NOTE: There are four flanges. mm fin.) No. Thickness [ Ne. Thickness None 5.0 (0.197) 2 5A (0.213) 1 5.2 (0.208) [3 5.6 (0.220) REMOVE FLANGE, DISCS AND PLATES (a) Remove the snap ring with a screwdriver. (b) Remove the flange, discs and plates. COMPRESS PISTON RETURN SPRING AND REMOVE SNAP RING {a) Place SST on the spring retainer and compress the return spring with a shop press. SST 09350-36010 (09350-06020) (b) Remove the snap ring with a screwdriver. REMOVE PISTON RETURN SPRING REMOVE SECOND BRAKE PISTON (a) Place matchmarks on the piston and center support and then place SST on the piston. (b) Holding SST so it is not slanted, apply compressed air into the passage to remove the 2nd brake piston. (c) Remove the 2nd brake piston and then remove the O-rings from the piston. SST 09360-36010 (09350-06020) REMOVE TWO OIL SEAL RINGS REMOVE THREE O-RINGS FROM OIL HOLES OF CENTER SUPPORTAUTOMATIC TRANSMISSION — Center Support AT-67 —Spring Retainer INSPECTION OF CENTER SUPPORT 1 CHECK DISCS Using a micrometer, measure the thickness of the discs. Minimum thickness: 1.9 mm (0.075 in.) If the thickness is less than the imum, replace the discs. CHECK PISTON RETURN SPRING Using calipers, measure the free length of the return spring, Standard length: 22.75 mm (0.8957 in.) CHECK CENTER SUPPORT BUSHINGS Using a dial indicator, measure the inside diameter of the center support bushings, Maximum inside diameter: 35.08 mm (1.3811 in.) If the inside diameter is greater than the maximum, replace the center support. ASSEMBLY OF CENTER SUPPORT 1 INSTALL OIL SEAL RINGS (a) Coat the two oil seal rings with ATF. (b) Contract the oil seals and install them onto the center support. CAUTION: Do not spread the ring ends more than necessary. NOTE: After installing the oil seal rings, check that they move smoothly. INSTALL THREE NEW O-RINGS Coat three new O-rings with ATF and install them to the oil holes of the center support. INSTALL NEW O-RINGS ON SECOND BRAKE PISTON Coat two new O-rings with ATF and install them on the 2nd brake piston. INSTALL SECOND BRAKE PISTON (a) Align the matchmarks on the piston and center sup- port, (b) Being careful not to damage the O-rings, press in the brake piston into the center support by both hands.AUTOMATIC TRANSMISSION — Center Support AT-68 c_ 5. c 6. 7. ate ay -pise | 8 Plate alae 10. __s] INSTALL PISTON RETURN SPRING COMPRESS PISTON RETURN SPRING AND INSTALL SNAP RING IN GROOVE (a) Place SST on the spring retainer, and compress the return spring with a shop press. SST 09350-36010 (09350-06020) (b) Install the snap ring with a screwdriver. Be sure the end gap of the snap ring is not aligned with the cut- out portion of the center support. INSTALL PLATES, DISCS AND FLANGE P—D—P—-D-P—D-P-D {b) Install the flange facing the rounded edge down. (a) Install in order INSTALL SNAP RING Be sure end gap of the snap ring is not aligned with the cutout portion of the center support. CHECK PISTON STROKE OF SECOND BRAKE (B1) Using SST and a dial indicator, measure the 2nd brake piston stroke, applying and releasing the compressed air (4-8 kg/em?, 57—114 psi or 392-785 kPa) as shown, SST 09350-36010 (09350-06120) Piston stroke: 1.60 — 1.80 mm (0.0630 — 0.0709 in.) If the piston stroke exceeds the limit, replace the discs and recheck the piston stroke. If the piston stroke is less than the limit, parts may be improperly assembled and require reassembly. If the piston stroke is nonstandard, select another flange. NOTE: There are four flanges. mm {in.) [ No. Thickness No. Thickness None 5.0 (0.197) 2 5.4 (0.213) 1 5.2 (0.205) [3 5.6 (0.220) INSTALL PLANETARY SUN GEAR Install the planetary sun gear and then install the snap ring.