Diagnostico y Overhaul A41 A40d Toyota Transmision

1983 Toyota Celica GT
1983 AUTOMATIC TRANSMISSIONS A-41, A-40D, A-43D & A-43DL Diagnosis & Overhaul
1983 AUTOMATIC TRANSMISSIONS
A-41, A-40D, A-43D & A-43DL Diagnosis & Overhaul
APPLICATION
TRANSMISSION APPLICATION
Application Transmission Model
Celica A-40D
Corolla
3-Speed A-41
4-Speed A-40D
Cressida A-43DL
Pickup A-43D
Supra A-43DL
IDENTIFICATION
NOTE: Information is not available.
DESCRIPTION
The A-41 transmission has 3 forward speeds and reverse. A-40D, A-43D and A-43DL transmissions have 4
forward speeds (4th is overdrive) and reverse. Cressida and Supra automatic transmission (A-43DL) uses an
electronic control unit (ECU). See Fig. 1 and Fig. 2 .
The torque converter is a 3-element type. Planetary gears are actuated by 3 multi-disc brakes and 2 clutches.
Engine load and speed determine gear changes by use of throttle valve position and output shaft speed. Tests,
specifications and repair procedures are the same except where noted.
These automatic transmissions have no bands, eliminating the need for internal adjustments. The only external
adjustments are throttle cable position, shift linkage adjustment and neutral start switch.
viernes, 30 de septiembre de 2016 8:32:33

8:32:27 a. m. Page 1 © 2011 Mitchell Repair Information Company, LLC.
Fig. 1: Transmission Electrical Components (Cressida)

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
viernes, 30 de septiembre de 2016 8:32:27 a. m. Page 2 © 2011 Mitchell Repair Information Company, LLC.
Fig. 2: Transmission Electrical Components (Supra)

LUBRICATION & ADJUSTMENTS
NOTE: See appropriate SERVICING article.
TROUBLE SHOOTING
NO MOVEMENT IN ANY FORWARD GEAR OR REVERSE
Manual linkage out of adjustment. ECU faulty (Cressida and Supra). Faulty valve body or primary regulator.
NO MOVEMENT IN ANY RANGE
Faulty parking lock pawl. Faulty valve body or primary regulator. Faulty torque converter. Converter drive plate
damaged or broken. Oil pump intake screen blocked. ECU faulty (Cressida and Supra).
SHIFT LEVER POSITION INCORRECT
Manual linkage out of adjustment. Faulty manual valve and lever.
HARSH ENGAGEMENT INTO ANY DRIVE GEAR
Throttle cable out of adjustment. Faulty valve body, primary regulator or accumulator pistons.
DELAYED 1-2, 2-3, 3-OD UPSHIFTS, OR DOWNSHIFTS FROM OD-3 OR 3-2 THEN BACK TO OD
OR 3
Throttle cable out of adjustment or faulty. Faulty governor or valve body. ECU or solenoid valve faulty
(Cressida and Supra).
SLIP ON ANY UPSHIFT OR SLIP OR SHUDDER ON TAKEOFF
Manual linkage or throttle cable out of adjustment. Valve body faulty. Solenoid valve faulty (Cressida and
Supra).
HARSH DOWNSHIFT
Throttle cable out of adjustment or faulty. Accumulator pistons or valve body faulty.
NO DOWNSHIFT WHEN COASTING
Faulty governor or valve body. ECU or solenoid valve faulty (Cressida and Supra).
DOWNSHIFTS TOO SOON OR TOO LATE WHEN COASTING
Throttle cable out of adjustment or faulty. Faulty governor or valve body. ECU or solenoid valve faulty
(Cressida and Supra).
NO OD-3, 3-2 OR 2-1 KICKDOWN
Throttle cable out of adjustment. Governor or valve body faulty. ECU or solenoid valve faulty (Cressida and
Supra).
NO ENGINE BRAKING IN "2"
Faulty valve body. Faulty ECU or solenoid valve (Cressida and Supra).
VEHICLE DOES NOT HOLD IN "P"
Manual linkage out of adjustment. Parking lock pawl cam and spring faulty.
CLUTCH & BAND APPLICATIONS
CLUTCH & BAND APPLICATIONS

Selector Lever Position Element In Use
"D" (Drive)
First (1) Front Clutch
Second Front Clutch & Brake No. 2

Third Front Clutch, (2) Rear Clutch &
Brake No. 2
"2" Second (Intermediate) Front Clutch, (3) Brake No. 1 & (4)
Brake No. 2
"L" Low (First) Front Clutch & (1) (5) Brake No. 3
Reverse Rear Clutch & Brake No. 2
Neutral Or Park All Clutches, Brakes & Bands Released
&/Or Ineffective
(1) One-way clutch No. 2 applied.
(2) Inner piston applied.
(3) Applied when engine is braking.
(4) One-way clutch No. 1 applied.
(5) Outer piston applied.
ELECTRICAL TESTS
NOTE: For ECU circuitry, see Fig. 47 .
ELECTRONIC CONTROL CIRCUIT
DG Terminal Voltage
1. With the engine warm, connect a voltmeter to DG terminal. See Fig. 1 and Fig. 2 . Place pattern selection
switch in "Normal" and shift selector to "D". During a road test, check that voltage at DG terminal for
each upshift is as indicated. See DG TERMINAL VOLTAGE table.
2. If DG terminal voltage is constant at 4 volts, speed sensor is faulty. If DG terminal voltage is constant at 8
volts, solenoid is defective.
3. Stop vehicle, but DO NOT turn off engine or diagnostic codes in ECU memory will be erased. With
engine running, recheck voltage at DG terminal.
4. To check throttle position sensor system, turn off engine. While slowly depressing accelerator pedal,
recheck voltage at DG terminal.
5. To inspect brake signal, depress accelerator until DG terminal voltage is 8 volts. Depress brake pedal and
check DG terminal voltage. See BRAKE SIGNAL DG TERMINAL VOLTAGE table.
DG TERMINAL VOLTAGE
Gear Position Voltage
1st 0
2nd 2
2nd & Lock-Up 3
3rd 4
3rd & Lock-Up 5
OD 6
OD & Lock-Up 7
BRAKE SIGNAL DG TERMINAL VOLTAGE

Brake Pedal Position Voltage
Depressed 0
Released 8
ECU Connector Voltage
Remove left kick panel (Cressida). Remove right pillar louver and arm rest (Supra). Turn ignition "ON".
Measure voltage at each terminal of automatic transmission ECU connector. See Fig. 46 . See WIRING
DIAGRAMS .
Solenoid
1. Disconnect connector from automatic transmission ECU. Measure resistance between S1 S2, S3, and
ground. Resistance should be 11-15 ohms.
2. Apply battery voltage to solenoid. Check if solenoid operates. If there is foreign material in solenoid
valve, there will be no fluid control even if solenoid operates.
Neutral Start Switch
Shift lever into "D" or "S". Disconnect neutral start switch connector near starter motor. Check that there is
continuity between L, S and ground.
Throttle Position Sensor
Disconnect connector from throttle position sensor and remove rubber. Check that there is continuity between
E1 and other terminals.
Speed Sensor
Jack up a rear wheel. Connect an ohmmeter between connector and ground. Spin wheel and check that
ohmmeter needle deflects from peg to peg.
Speedometer (Analog Type)
Remove speedometer from instrument panel. Connect an ohmmeter between SP terminals. Rotate speedometer
shaft and check that ohmmeter needle deflects from peg to peg.
Speedometer (Digital Type)
Remove speedometer. Apply battery voltage between terminals IG(+) and IG(-). Connect a voltmeter between
terminal SP and GND. Rotate speedometer shaft and check that voltmeter needle deflects from 0 to 10 volts.
Pattern Selection Switch
On Cressida, check that there is continuity between terminal No. 2 and other terminals. On Supra, check that
there is continuity between terminals No. 3 and 4.
Lock-Up Mechanism
With engine and transmission warm, connect a voltmeter to DG terminal. See Fig. 1 and Fig. 2 . Select
"Normal" pattern. Drive at about 30 MPH so voltmeter reads 3 or 7.5 volts (lock-up range). Depress accelerator
pedal and note tachometer. If RPM jumps considerably, there is no lock-up.
PERFORMANCE TESTS
ROAD TEST
1. To check full throttle upshift points in "D" range, start from dead stop and observe speedometer speeds at
shift points and throttle openings specified. Speeds at shift point should be approximately as specified in
SHIFT SPEED SPECIFICATIONS .
2. While running in "D" or OD gear, shift to "2" and "L" ranges and check engine braking effect at these
ranges. If there is no engine braking at "2" range, brake No. 1 is defective. If there is no engine braking at
"L" range, brake No. 3 is defective.
3. While running in "D" range, release foot from accelerator and shift into "L" range. Check that OD-3, 3-2
and 2-1 downshift points conform to those in SHIFT SPEED SPECIFICATIONS .
4. Check upshift points at half throttle. Shift points should be about 20 MPH lower than at full throttle.
Drive vehicle in "2" range at half throttle. Observe speed of 1-2 upshift. Shift should occur at about same
speed as in "D" range.
5. With transmission in "L", accelerate to about 40 MPH. Transmission should remain in "L" until lever is
moved to next range.
SHIFT SPEED SPECIFICATIONS
SHIFT SPEED SPECIFICATIONS

Shift Condition Shift Point (MPH)
Celica
1-2 Upshift In "D" 36-45
3-OD Upshift In "D" (1) 80-85
3-2 Downshift In "D" 57-67

2-1 Downshift In "L" 29-40
Corolla
A-41 Transmission (3.73:1 Axle Ratio)
A-40D Transmission (3.91:1 Axle Ratio)
3-OD Downshift In "D" (1) 24-32

Cressida (2)
3-OD Upshift In "D" 86-90
Pickup
1-2 Upshift In "D" (3) 35-45
2-3 Upshift In "D" (3) 76-86
3-OD Upshift In "D" (1) 69-79
3-2 Downshift In "D" (3) 57-66
2-1 Downshift In "D" (3) 10-33
Supra (2)
3-OD Upshift In "D" 86-90
(1) 3-OD upshifts will not occur at full throttle. 3-OD upshift speeds shown are at about 70 percent
throttle on Celica and Pickup, closed throttle on Corolla.
(2) With throttle valve fully open and "Normal" range pattern.
(3) At about 60 percent throttle valve opening.
HYDRAULIC PRESSURE TESTS
With transmission fluid at normal operating temperature, raise and support rear of vehicle so that rear wheels
are free to turn. Connect pressure gauges to line pressure and governor pressure test ports on transmission. See
Fig. 3 .
Governor Pressure
1. Start engine and release parking brake. Slowly accelerate engine with transmission in "D" and check
governor pressure at specified speeds. See GOVERNOR PRESSURE SPECIFICATIONS table.
2. If governor pressures are incorrect, check for the following: incorrect line pressure, fluid leakage in
governor pressure circuit, governor valve operation defective.
GOVERNOR PRESSURE SPECIFICATIONS

Vehicle Speed Output Shaft (RPM) Pressure psi (kg/cm2 )
(MPH)
18-21 1000 12.8-21.3 (0.9-1.5)
34-36 1800 22.8-31.3 (1.6-2.2)
65-70 3500 58.3-75.4 (4.1-5.3)
Fig. 3: View Of Transmission Case Showing Hydraulic Pressure Test Ports

Line Pressure
1. Fully apply parking brake and block all 4 wheels. Start engine and shift transmission into "D". Apply firm
pressure to brake pedal and let engine idle. Line pressure should be as specified. See LINE PRESSURE
SPECIFICATIONS table.
2. Increase engine to stall speed and recheck line pressure. If specified line pressures are not obtained, check
throttle cable adjustment and repeat test.
3. Repeat line pressure tests with transmission in "R". Line pressures should be as specified. See LINE
PRESSURE SPECIFICATIONS table.
LINE PRESSURE SPECIFICATIONS

Engine Pressure psi (kg/cm2 )
Speed
At Idle
"D"
Cressida 53-58 (3.7-4.1)
& Supra
All 57-64 (4.0-4.5)
Other
Models
"R"
Cressida 73-81 (5.1-5.7)
& Supra
All 82-97 (5.8-6.8)
Other
Models
At Stall Speed
"D"
Cressida 151-185 (10.6-13.0)
& Supra
All 135-171 (9.5-12.0)
Other
Models
"R"
Cressida 203-270 (14.3-19.0)
& Supra
All 199-242 (14.0-17.0)
Other
Models
Line Pressure Test Results
1. If line pressure in all ranges is higher than specified, check for the following: defective regulator valve,
defective throttle valve, or throttle cable out of adjustment.
2. If line pressure is low in all ranges, check for the following: defective oil pump, defective regulator valve,
defective throttle valve, throttle cable out of adjustment, or defective OD clutch.

3. If line pressure is low in "D" range only, check for the following: defective front clutch, fluid leak in "D"
range circuit, or defective OD clutch.
4. If line pressure is low in "R" range only, check for the following: defective rear clutch, defective No. 3
brake, fluid leak in "R" range circuit, or defective OD clutch.
STALL TEST
1. With engine and transmission at normal operating temperature, connect a tachometer to engine. Apply
parking brake and block front wheels.
NOTE: DO NOT maintain stall RPM for more than 5 seconds.
2. Start engine, apply brake pedal and place transmission in "D". Accelerate engine to full throttle and check
maximum speed obtained. Repeat test in "R". Record stall speeds. See STALL TEST
SPECIFICATIONS table.
STALL TEST SPECIFICATIONS

Application Stall RPM
Celica & Corolla 1850-2150
Cressida & Supra 1950-2250
Pickup 1700-2000
Stall Test Results
1. If stall is the same for both ranges but lower than specified, engine output may be insufficient, or stator
one-way clutch may not be operating properly.
NOTE: If stall RPM is more than 600 RPM lower than specifications, torque
converter may be faulty.
2. If stall speed is higher than specified in "D" range, front clutch may be slipping, one-way clutch No. 2
may not be operating, line pressure may be low, or OD one-way clutch may not be operating.
3. If stall speed in "R" is higher than specified, rear clutch and/or brake No. 3 may be slipping, line pressure
may be low, OD clutch or OD one-way clutch may not be operating.
COMPONENT TESTS
TORQUE CONVERTER
Converter Flushing
If transmission appears contaminated, thoroughly flush converter with transmission cleaner before reassembly.
Clean outside of converter and case.
One-Way Clutch Test
1. With converter placed on work surface, insert special tool kit (SST 09350-20010). Kit consists of 2
pieces: a turning tool and a stopper. Insert turning tool in inner race of one-way clutch. Insert stopper to
fit in notch of converter hub and other race of one-way clutch.
2. Clutch should lock when turned counterclockwise, but should turn freely when rotated clockwise. Torque
required to turn clutch clockwise should be less than 22 INCH lbs. (2.5 N.m). If necessary, clean
converter and retest clutch. Replace converter if clutch still fails test.
REMOVAL & INSTALLATION

The following components can be removed and installed on transmission with transmission installed in vehicle:
oil pan, valve body assembly, throttle cable, parking pawl assembly, manual valve shaft oil seal, speedometer
drive gear, rear oil seal, speedometer driven gear, governor assembly and speed sensor. For removal procedures,
see TRANSMISSION DISASSEMBLY , COMPONENT DISASSEMBLY & REASSEMBLY and
TRANSMISSION REASSEMBLY .
EXTENSION HOUSING & ROTOR SENSOR
Removal
Remove propeller shaft. Support transmission with a jack and raise slightly to remove weight from rear support.
Disconnect speedometer cable. Remove speedometer driven gear. Remove speed sensor. Remove ground strap,
exhaust hanger and rear support member. Remove extension housing. Remove rotor sensor from output shaft.
Installation
Install rotor sensor on output shaft, making sure key is installed in groove. To complete installation, reverse
removal procedure.
SOLENOID
Removal & Installation
With transmission exterior clean and fluid drained, remove oil pan, filler tube and gasket. Remove oil tubes.
Disconnect 2 connectors from each solenoid. Remove solenoid (and gaskets from No. 1 and 2 solenoids). DO
NOT remove the 2 valve springs. To install, reverse removal procedure.
TRANSMISSION DISASSEMBLY
1. With torque converter removed, remove solenoid retaining bolts and solenoid (Celica, Corolla and
Pickup). On Cressida and Supra, remove speedometer driven gear and speed sensor.
2. Remove shift handle and neutral start switch. Remove front pump housing bolts. Pull oil pump assembly
from transmission case using a puller (SST0910-20012).
3. Grab oil pump by stator shaft and pull pump out of case. Remove bell housing retaining bolts (2 short, 4
long). Hold input shaft and remove converter.
4. Remove speedometer driven gear housing. Remove extension housing and gasket. Remove speedometer
gear snap ring. Remove drive gear, lock ball and other snap ring.
5. On Celica, Corolla and Pickup, remove governor retaining bolt (if equipped). Pry up on governor retainer
spring with a screwdriver and pull off governor. See Fig. 4 .
6. On Cressida and Supra, remove rotor sensor and snap ring from output shaft.
7. Remove oil pan retaining bolts. Remove pan by lifting case. DO NOT turn transmission over to remove
pan as this will contaminate valve body with dirt. On all except A-41, after removing oil pan, turn
transmission over and remove oil tubes. Note installation position for reassembly reference.
8. On Cressida and Supra, disconnect connector from No. 1 and 2 solenoids and No. 3 solenoid. Remove
grommet from transmission case. Pull solenoid wiring from case.
9. On all models, remove oil strainer. Remove valve body attaching bolts. Carefully lift up valve body and
disconnect throttle cable from throttle cam. Remove valve body from case. Hold throttle cable retainer
with a 10 mm socket and pull cable from case.
10. Remove accumulator pistons and spring from case by blowing compressed air through holes in case. See
Fig. 5 and Fig. 6 . Position a rag to catch piston when removing. Identify each accumulator piston and
spring for reassembly reference.
Fig. 4: Governor Assembly Removal

Fig. 5: Removing Accumulator Pistons & Springs (A-43D & A-43DL Transmissions)
Fig. 6: Removing Accumulator Pistons & Springs (A-41 & A-40D Transmissions)
11. Remove attaching bolts and parking lock pawl bracket. Remove lock rod after aligning lugs with manual
valve lever. Remove parking pawl, pivot pin and spring. Pry manual shift lever shaft over to gain access
to retaining pin. Drive out pin and remove shaft.
12. On all models except A-41, turn transmission over, grasp shaft and remove OD clutch. Hold both sides of
OD case and remove from transmission case with brake. Watch for bearings and races on both sides of
assembly. On all models, remove front clutch and bearings.
13. Remove rear clutch. Remove 2 center support mounting bolts at valve body side of case. Pull center
support and sun gear shaft assembly from case. Using a screwdriver, remove large snap ring from case
groove.
14. Pull rear parts group from transmission case by intermediate shaft. See Fig. 7 . If brake apply tube did not
come out with rear parts group, remove it from case. Remove output shaft thrust bearing and race from
inside of case.
Fig. 7: Removing Rear Parts Group

COMPONENT DISASSEMBLY & REASSEMBLY
OIL PUMP & STATOR SHAFT
Disassembly
Set pump shaft in torque converter while working on pump. Remove 2 oil seals from pump cover and discard.
Remove retaining bolts and washers and lift off pump cover. Remove large "O" ring from pump body. Mark
drive and driven gears for reassembly reference and remove from pump body. Pry out front oil seal. See Fig. 8 .
Inspection
1. Wash disassembled parts and blow dry with compressed air. Inspect pump oil seal and transmission seal
ring for damage.
2. Inspect contacting surfaces between body and driven gear for ridged wear. Check gears for wear and body
crescent for damage. Check pump gear contacting surface on stator shaft for damage and wear.
3. With a feeler gauge, measure clearance between driven gear and oil pump housing with gear pushed over
to other side. See Fig. 9 . Clearance should be .003-006" (.07-.15 mm). If clearance exceeds .012" (.3
mm), replace pump.
4. Measure clearance between crescent and driven gear (gear tip clearance). Clearance should be .004-
.006" (.11-.14 mm). If clearance exceeds .012" (.3 mm) replace oil pump.
5. Using a feeler gauge and straightedge, measure gear side clearance between pump body face and top of
gears. Clearance should be .001-.002" (.02-.05 mm). If clearance exceeds .004" (.1 mm) replace oil pump
assembly.
Fig. 8: Exploded View Of Oil Pump & Stator Shaft Assembly

Fig. 9: Measuring Oil Pump Gear Clearances

Reassembly
1. Coat drive and driven gears with automatic transmission fluid, then install them into pump body, aligning
marks made at disassembly.
2. Assemble stator shaft to pump body, then install, but do not tighten attaching bolts. Using oil pump
aligning tool (SST09350-20013) to align centers of stator shaft and oil pump body. Tighten attaching
bolts. Install 2 new oil seal rings on pump cover.
3. With pump body and stator shaft assembled, check drive gear with a screwdriver to ensure it rotates
freely. Lubricate and install "O" ring on pump body diameter. Check drive gear operation with
screwdriver. Gear should rotate freely.
OVERDRIVE CASE & BRAKE (ALL EXCEPT A-41)
Disassembly
1. Remove race from overdrive. Pry large snap ring from case. Lift out clutch flange, clutch discs, plates and
cushion plate. Retain in correct order for reassembly.

2. Remove ring gear. Pry thrust washer from ring gear. Remove thrust bearings and races from case and
note order and position for reassembly. Compress piston return springs and remove snap ring. Lift out
piston return springs and seat.
3. Remove brake piston from case by applying compressed air. See Fig. 10 . Remove oil seals from case and
"O" rings from piston.
Fig. 10: Using Compressed Air To Remove Piston From Overdrive Clutch Case
Inspection
1. Wash all parts (except discs) thoroughly in clean solvent. Air dry parts with compressed air.
2. Inspect all parts for wear or damage and replace as necessary. Inspect clutch plates, discs and flange for
signs of burning. Check piston return springs for wear, damage and collapsed coils.
NOTE: Do not let discs dry out. Soak new clutch discs in ATF for at least 2 hours
before installation.
Reassembly
1. Coat all surfaces with transmission fluid for assembly. Lubricate and install oil seals on overdrive case.
Install new "O" rings on brake piston. Carefully install piston (cup side up) into case. Save thrust washer
for installation when transmission is reassembled.

2. Position return springs into pockets of clutch piston, then install spring seat over springs. Compress return
springs and install retaining snap ring, making sure snap ring ends are not aligned with a slot in housing.
3. Install bearing and races on ring gear in same positions as before disassembly. See Fig. 12 . Install ring
gear assembly into clutch case.
4. Install cushion plate into clutch case with beveled side down. Install clutch pack into case starting with an
externally splined plate and alternating plates and discs. See Fig. 11 .
5. Install flange into clutch case with raised portion of flange facing up. Install clutch pack retaining snap
ring into groove in case and ensure it seats. Make sure snap ring ends are not aligned with a slot in
housing.
6. Using a feeler gauge, measure clutch pack clearance between flange and snap ring. Clearance should
be .014-.063" (.35-1.6 mm), with a maximum clearance of .083" (2.1 mm) allowed.
Fig. 11: Exploded View Of Overdrive Case & Brake

Fig. 12: View Of Ring Gear Showing Correct Installation Of Bearings & Races
OVERDRIVE INPUT SHAFT & CLUTCH (ALL EXCEPT A-41)
Disassembly
1. Remove thrust bearings and races from clutch side by hand. Note position of races. Pry thrust washer
from planetary gear side with a screwdriver. On A-40D, remove snap ring and hub from overdrive clutch
assembly.
2. Pull overdrive clutch assembly from input shaft. Remove thrust bearing and race (A-43D and A-43DL).
Remove snap ring and hub from overdrive clutch assembly. On all models, remove thin snap ring, flange
disc and plate. See Fig. 14 .
3. Compress piston return springs and remove snap ring. Remove spring retainer and 18 springs. Assemble
overdrive clutch on oil pump and blow out piston with compressed air. See Fig. 13 . Remove overdrive
clutch from oil pump. Remove clutch piston "O" rings.
4. Remove snap ring from overdrive planetary gear assembly. Remove thrust washers and one-way clutch
from planetary gear assembly. Remove plugs with a magnet, being careful not to lose plugs. Remove one-
way clutch from outer race.
Fig. 13: Removing Overdrive Direct Clutch

Fig. 14: Exploded View Of Overdrive Input Shaft & Clutch

Inspection
Thoroughly clean all parts and inspect them for wear and damage. Check clutch plates for signs of burning.
Shake piston to make sure check ball is free. Apply low pressure compressed air to check that valve does not
leak. Replace parts as necessary.
NOTE: Do not let discs dry out. Soak new clutch plates and discs in ATF for at least 2
hours before installation.
Reassembly
1. Lubricate all parts with transmission fluid before installation. Install the 4 plugs. On A-43D and A-43DL,
install thrust washer and bearing. Coat parts with petroleum jelly to keep in place and slip bearing and
thrust washer on with lip facing outward.
2. On all models, install one-way clutch into outer race. Install a retainer on both sides of one-way clutch.
Spring cage side of one-way clutch faces toward front of transmission. See Fig. 15 . Install thrust washer
and one-way clutch.
3. On A-40D, install thrust washer with the oil groove facing upward. On all models, install new "O" ring to
piston and lubricate with ATF. Press clutch piston into overdrive clutch drum with cup side up. Position
return springs into pockets of piston, then install spring seat over springs.
4. Using a compressor tool, compress springs and seat and install retaining snap ring. Install clutch plates
and discs into clutch drum in reverse order as removed. DO NOT install thin retaining snap ring yet.
5. To check piston travel, temporarily install overdrive clutch hub and outer snap ring. Install front clutch
drum on oil pump body. Mount a dial indicator so indicator tip touches top of clutch piston. See Fig. 16 .
6. Apply pressure to oil hole in oil pump and read piston travel on dial indicator. Piston travel with 57-114
psi (4-8 kg/cm2 ) air pressure applied should be .061-.090" (1.55-2.28 mm). If stroke exceeds limit, clutch
pack is probably worn. If stroke is less than specified, parts may be misassembled or there may be excess
ATF on discs.
7. Remove dial indicator. Remove overdrive clutch outer snap ring and hub to install inner snap ring. Install
thin inner snap ring in overdrive clutch drum. Check that snap ring ends are not aligned with cutouts.
8. On A-43D and A-43DL, install hub and outer snap ring. Check that snap ring ends are not aligned with
cutouts. On all models, assemble overdrive clutch drum and overdrive planetary gear. Mesh hub with
disc, twisting hub as necessary.
9. On A-40D, install hub and outer snap ring. Check that snap ring ends are not aligned with cutouts. On all
models, check operation of one-way clutch. Hold clutch drum and turn input shaft. Input shaft should turn
freely clockwise and lock counterclockwise.
Fig. 15: View Showing Correct Installation Of One-Way Clutch Assembly

Fig. 16: Checking Clutch Piston Travel

FRONT CLUTCH
Disassembly
1. Remove thrust bearing and races from both sides of clutch. Note position of races. Use extension housing
as a work stand for remainder of disassembly. Remove snap ring and lift out both clutches together.
Remove thrust bearings and races. See Fig. 18 . Remove clutch plate on A-41 and A-40D or disc on A-
43D and A-43DL.
2. Remove thin snap ring and pull out remaining clutch plates and discs. Using a compressor tool, compress
piston return spring and remove snap ring. Take out spring seat and return springs.
3. On A-41 transmissions, assemble clutch drum onto oil pump, then remove clutch piston from drum by
applying compressed air to oil pump oil hole. See Fig. 17 . Remove "O" rings from piston.
4. On all other transmissions, assemble clutch drum onto overdrive clutch case, then remove piston by
applying compressed air to case oil hole. See Fig. 17 . Remove "O" rings from clutch piston.
Fig. 17: Removing Front Clutch Piston Using Compressed Air

Fig. 18: Exploded View Of Front Clutch Assembly

Inspection
1. Thoroughly clean all parts and inspect for wear and damage. Check clutch plates and discs for signs of
burning and replace as necessary.
NOTE: Soak new clutch plates in ATF for at least 2 hours before installation.
2. Check input shaft bearing and bushing contacting surfaces for damage, excessive wear and burning. Insert
input shaft into torque converter and ensure it slides in smoothly without being loose.
3. Inspect toothed parts of clutch drum and clutch hubs for wear and damage. Inspect piston and clutch drum
sliding surfaces for burning.
4. Check return springs for wear, damage or collapsed coils. Check for uniform spring length and replace
spring if one is noticeably shorter than others. Replace any worn or damaged springs.
5. Inspect check ball in clutch piston for sticking by shaking piston. Apply compressed air from inner side of
piston and inspect check ball for air leaks.
Reassembly
1. Lubricate and install new "O" ring onto clutch piston. Carefully install piston into clutch drum. Position
piston return springs and seat on piston, then compress springs and install snap ring.
2. Blow excess ATF off of clutch discs and plates with low pressure compressed air. Install ALL clutch
discs and plates into drum without thin snap ring. Install rear clutch hub and outer snap ring. Make sure
snap ring ends do not align with any slot in clutch drum.
3. On A-41 transmissions, install clutch drum on oil pump body. On A-40D and A-43DL, install clutch on
the overdrive case. Apply 57-114 psi (4-8 kg/cm2 ) air pressure to oil hole in pump body or overdrive
case. Assemble a dial indicator with tip touching clutch piston.
4. Piston stroke on A-41 and A-40D models should be .056-.092" (1.42-2.33 mm). On A-43D and A-43DL
models, piston stroke should be .072-113" (1.84-2.86 mm). If stroke is longer, clutch pack may be worn.
If stroke is too short, component may be assembled improperly or there may be excess ATF on clutch
discs.
5. Remove snap ring and rear clutch hub. Remove 2 plates and a clutch disc from A-41, a plate and disc
from A-40D, or a disc from A-43D and A-43DL. Install thin snap ring and reinstall parts just removed.
6. Coat inner thrust bearing and races with petroleum jelly to hold them in place and install. Make sure lip of
race faces toward front clutch body. Install front clutch hub, rear clutch hub and snap ring. Check that
snap ring ends do not align with slot in clutch drum.
7. Set remaining thrust bearings and races aside for installation when transmission is reassembled.
REAR CLUTCH
Disassembly
1. Remove snap ring and lift clutch flange, clutch discs and clutch plates from rear clutch drum. Compress
piston return spring with compressor tool and remove snap ring. Lift out springs and spring seat.
2. Assemble clutch drum on center support. Apply compressed air to oil hole(s) in center support and
remove inner and outer pistons (rear clutch piston on A-43D and A-43DL models) from clutch drum. See
Fig. 19 . Remove "O" rings from piston(s) and discard.
Fig. 19: Using Compressed Air To Remove Rear Clutch Inner & Outer Pistons
Inspection
1. Thoroughly clean all parts and inspect them for wear and damage. Inspect toothed parts and piston sliding
surfaces of clutch drum for wear or damage.
2. Inspect clutch plates and discs for signs of burning. Check plate and disc splines (teeth) for wear and
damage.
3. Inspect clutch pistons for wear and damage. Shake pistons and make sure check balls are free. Apply air
pressure to check balls and check for leakage. Check piston return springs for even length.
Reassembly
1. Install "O" rings on inner and outer pistons. Apply a thin coat of ATF to "O" rings, then insert pistons
carefully into clutch drum, making sure not to damage "O" rings.
2. Place piston return springs and spring seat on piston. Compress springs and install snap ring. Install clutch
plates, clutch discs and clutch flange into drum in correct sequence. See Fig. 20 . Install clutch pack snap
ring.
NOTE: Install clutch flange with raised portion facing forward.
3. Install rear clutch onto center support. Apply compressed air pressure of 57-114 psi (4-8 kg/cm2 ) to oil
hole in center support and measure travel with a dial indicator. See Fig. 21 . Piston travel should be .037-
.068" (.93-1.72 mm) on A-41 and A-40D, .043-051" (1.10-1.30 mm) on A-43D and .049-084" (1.24-2.12
mm) on A-43DL.
4. Excessive travel indicates worn clutch pack. If travel is below specifications, components may be
misassembled or there may be excess ATF on clutch discs.
Fig. 20: Exploded View Of Rear Clutch Assembly

Fig. 21: Checking Rear Clutch Piston Travel

CENTER SUPPORT ASSEMBLY
Disassembly (A-41 Transmission)
1. Remove snap ring from end of planetary sun gear, then remove center support assembly from shaft.
Remove snap ring from front of center support assembly (No. 1 brake). See Fig. 22 .
2. Remove clutch flange, disc and plate (No. 1 brake). Compress piston return springs and remove snap ring.
Remove spring retainer and 12 springs. Turn over center support on top of rag, with piston facing down.
3. Blow compressed air through center support oil hole to remove No. 1 brake piston. Remove brake piston
"O" rings. Turn center support assembly over and remove rear snap ring (No. 2 brake). Remove clutch
flange, discs and plates (No. 2 brake).
4. Compress piston return springs and remove snap ring. Remove spring retainer and 12 springs. Turn over
center support on top of rag, with piston facing down. Blow compressed air through center support oil
hole and remove No. 2 brake piston.
5. Remove brake piston "O" rings. Remove 3 oil seal rings from center support. Remove one-way clutch
assembly and oil seal rings from sun gear.
Inspection
Hold No. 2 brake hub and turn sun gear. Sun gear should turn freely counterclockwise and lock clockwise. If
one-way clutch does not work properly, replace it.
Reassembly
1. Assemble oil seal rings and one-way clutch on sun gear. Check operation of one-way clutch. Sun gear
should turn freely counterclockwise and lock when turned clockwise. Install 3 oil seal rings on center
support.
2. Install new "O" rings on piston. Press No. 1 brake piston in center support with cup side up. Install 12
piston return springs and set retainer and snap ring in place. Compress springs and install snap ring.
3. Install new "O" rings on piston and center support. Turn center support over and install new brake piston.
Press No. 2 brake piston into center support with cup side up, being careful not to damage "O" rings.
Install 12 piston return springs and set retainer with snap ring into place.
4. Compress springs and install snap ring. Turn center support over and install No. 1 brake piston plate, disc
and flange (rounded edge down). Install snap ring in center support. Check that snap ring ends are not
aligned with a cut-out.
5. Install a dial indicator to measure piston stroke. Apply compressed air to piston oil hole at 57-114 psi (4-8
kg/cm2 ) and measure stroke. Stroke should be .026-051" (.65-1.30 mm). Excessive travel indicates worn
clutch pack. If travel is below specifications, components may be misassembled or there could be excess
ATF on clutch discs.
6. Turn center support over and install No. 2 brake plates, discs and flange. Use low pressure compressed air
to blow excess ATF from discs. Install in this order: plate, disc, plate, plate, disc, flange (rounded edge
down). Install snap ring in center support. Check that snap ring ends are not aligned with a cut-out.
7. Install dial indicator to measure piston stroke of No. 2 brake. Apply compressed air to piston oil hole at
57-114 psi (4-8 kg/cm2 ) and measure stroke. Stroke should be .037-.068" (.93-1.72 mm). Excessive
travel indicates worn clutch pack.
8. If travel is below specifications, components may be misassembled or there could be excess ATF on
clutch discs. Assemble center support and sun gear shaft. Align No. 2 disc flukes. Mesh brake hub with
discs, twisting as necessary. Install snap ring on end of sun gear shaft.
Fig. 22: Exploded View Of Center Support Assembly (A-41 Transmission)

Disassembly (A-40D & A-43D Transmission)
1. Remove snap ring from end of planetary sun gear, then pull sun gear from center support.
2. Remove retaining snap ring, then lift flange, discs and plates for No. 1 brake from center support. Note
order for reassembly reference. Compress 16 piston return springs and remove snap ring, then remove
return springs and spring seat from center support. See Fig. 23 .
3. Using compressed air, remove No. 1 brake piston from center support by blowing in oil holes in center
support. Remove "O" rings from piston. Remove oil seal rings from center support. Remove oil seal rings
from sun gear.
Inspection
Inspect all parts for wear or damage. Check plates and discs for signs of burning. Check free length of return
springs. Replace any spring that is noticeably shorter than others.
Reassembly
1. Install 2 oil seal rings on sun gear. Install 3 oil seal rings on center support. Install new "O" rings on
piston and center support. Press No. 1 brake piston into center support with cup side up. Install 16 piston
return springs and set retainer with snap ring into place.
2. Compress springs and install snap ring with a screwdriver. Use low pressure compressed air to blow ATF
from discs and install No. 1 brake plates, discs and flange. Install in order noted during disassembly.
Install flange with flat end down.

3. Install snap ring in center support. Check that snap ring ends are not aligned with a cut-out. Install dial
indicator to measure piston stroke. Apply compressed air to piston oil hole at 57-114 psi (4-3 kg/cm2 )
and measure stroke. Stroke should be .039-.047" (1.0-1.2 mm).
misassembled or there could be excess ATF on clutch discs. Assemble center support and sun gear shaft.
Install snap ring on end of sun gear shaft.
Fig. 23: Exploded View Of Center Support Assembly (A-40D & A-43D Transmissions)
Disassembly (A-43DL Transmission)
1. Remove snap ring from end of sun gear shaft. Pull center support assembly from shaft. Remove snap ring
from front of center support assembly. Remove clutch flange, disc and plate (No. 1 brake). Compress
piston return springs and remove snap ring. See Fig. 24 .
2. Remove spring retainer and 12 springs. Blow compressed air through center support oil hole to remove
No. 1 brake piston. Remove No. 1 piston "O" rings. Turn center support assembly over and remove rear
snap ring (No. 2 brake). Remove clutch flange, discs and plates (No. 2 brake).
3. Compress piston return springs and remove snap ring. Remove spring retainer and springs. Remove No. 2
brake piston by blowing compressed air through center support oil hole. Remove No. 2 brake piston "O"
rings. Remove 3 oil seal rings from center support. Remove one-way clutch assembly and seal rings from
sun gear.
Inspection
Inspect all parts for wear or damage. Check plates and discs for signs of burning. Check free length of return
springs. Replace any spring that is shorter than others.
Reassembly
1. Install 2 oil seal rings and one-way clutch assembly on sun gear. Install 3 oil seal rings on center support.
Install new "O" rings on piston. Install No. 1 brake piston in center support with cup side up. Install 12
piston return springs and set retainer in place.
2. Compress springs and install snap ring. Install new "O" rings on piston and center support. Turn center
support over and install No. 2 brake piston into center support with cup side up. Install 12 piston return
springs and retainer. Compress return springs and install snap ring.
3. Turn center support over and install No. 1 brake piston plate, disc and flange. Install flange with rounded
edge down. Install snap ring to center support. Apply compressed air to piston oil hole at 57-114 psi (4-8
kg/cm2 ) and measure stroke of No. 1 brake. Stroke should be .039-.047" (1.0-1.2 mm) for A-43D
and .039-.068" (1.0-1.7 mm) for A-43DL.
misassembled or there could be excess ATF on clutch discs. Turn center support over and install No. 2
brake plates, disc and flange in order removed. Install snap ring in center support, making sure ends are
not aligned with a cut-out.
5. Test piston stroke of No. 2 brake in same manner as No. 1 brake. Stroke should be .049-.068" (.93-1.72
mm). Excessive travel indicates worn clutch pack. If travel is below specifications, components may be
misassembled or there could be excess ATF on clutch discs. Align No. 2 brake disc flukes. Assemble
center support and sun gear shaft. Install snap ring on end of sun gear shaft.
Fig. 24: Exploded View Of Center Support Assembly (A-43DL Transmission)

PLANETARY GEAR OUTPUT SHAFT
Disassembly
1. Remove No. 3 brake disc/plate pack and front planetary pinion gears. Remove thrust washer, brake discs
and plates from planetary gears. Remove reaction plate, snap ring and one-way clutch. Remove nylon
thrust washer.
2. Remove apply tube and clutch pressure plate. See Fig. 25 . While pulling up on ring gear, compress and
remove snap ring from ring gear. Remove ring gear. Remove intermediate shaft from output shaft.
Remove thrust bearing and races from output shaft, noting position of races.
3. Remove 3 oil seal rings from output shaft. From intermediate shaft, remove nylon thrust washer (steel on
A-43DL) and rear pinion gears. Remove race and thrust bearing from intermediate shaft, noting position
of race. Invert intermediate shaft and remove set ring. Remove rear planetary ring gear and bearing race
from intermediate shaft.
Fig. 25: Exploded View Of Output Shaft & Planetary Gears

Inspection
1. Do not allow discs to dry out. Soak new discs at least 2 hours in ATF. Inspect thrust washers for wear,
warpage and burning. Inspect carrier thrust surfaces for warpage and wear. Check planetary pinions for
wear and damage.
2. Inspect one-way clutch outer race surface in carrier for wear. Check reaction plate toothed part and
sliding surface for wear and damage. Check one-way clutch sliding surface or reaction plate for wear and
damage.
Reassembly
1. Slip thrust bearing race and rear planetary ring gear onto shaft with exterior splines up. Install set ring on
intermediate shaft. Turn over intermediate shaft and install thrust bearing and race.
2. Install pinion gear assembly thrust washer on rear planetary carrier (nylon washer on A-41 and A-40D,
steel on A-43D and A-43DL). Install washer with lugs down, fitting into rear planetary carrier. Make sure
lug shapes match opening on plate. Install 3 oil seal rings on output shaft.
3. Using extension housing as an assembly stand, install thrust bearing and race on output shaft. Hold race
cup toward bearing. Install intermediate shaft assembly in output shaft. Install rear planetary carrier in
output shaft. Slide into place and make sure lugs interlock.
4. Install snap ring on front planetary ring gear. Align ends of snap ring with wide gap between teeth. Install
ring gear on shaft and while pushing down on ring gear, squeeze ends of snap ring and install into groove.
When snap ring is fully seated, gap is one lug wide.
5. Install nylon thrust washer in front planetary gear. Face lugs down and match them with slots in back of
planetary gear. Install one-way clutch into outer race with spring cage toward front. Install snap ring.
6. Temporarily install one-way clutch inner race on planetary gear and check clutch operation. Planetary
gear should rotate freely clockwise and lock when turned counterclockwise. Remove inner race. Install
thrust washer on planetary gear, matching lugs with planetary carrier while installing.
7. Hold washer in place with petroleum jelly for later assembly. Install planetary gear assembly on
intermediate shaft. Make sure pinion gears mesh fully with ring gear. Install pressure plate with flat
surface toward intermediate shaft.
8. Install clutch pack discs and plates in same order as before removal. Keep inner race apply tube, thrust
bearing and race together for installation when transmission is reassembled.
REAR BRAKE PISTON
Disassembly
1. Using compressor tool (SST09350-29913), compress piston return springs and remove snap ring. Remove
spring retainer, return springs and compressor tool. See Fig. 26 . Position transmission with front opening
facing down.
2. Using 2 air guns, blow SIMULTANEOUSLY through brake cylinder holes and remove inner piston,
outer piston and brake reaction sleeve as a unit. See Fig. 27 .
Fig. 26: Exploded View Of Rear Brake Assembly

Fig. 27: Removing Rear Brake Piston

Inspection
Wash all parts in clean solvent and blow dry with compressed air. Inspect piston and reaction sleeve for scoring,
wear or other damage. Check return springs for uniform height and cracked or broken coils. Replace any
damaged parts.
Reassembly
1. Install new "O" rings to reaction sleeve and pistons. Thin "O" ring goes on outside of reaction sleeve.
Install inner and outer pistons on reaction sleeve. Push inner piston into cupped side of reaction sleeve.
Push outer piston onto other side of reaction sleeve.
2. Install pistons and sleeve in case by holding assembly with outer piston up and push assembly into its
bore in case. Using same tools as for removal, install spring retainer, compress springs and install snap
ring.
VALVE BODY
NOTE: For exploded views of valve bodies, see Fig. 28 , Fig. 34 and Fig. 41 .
Disassembly
NOTE: Disassembly procedures for all valve bodies are similar. Use appropriate valve
body figure as a guide and note the following procedures.
1. As valve trains are removed from each valve body bore, place individual parts in correct order in relative
position to valve body in order to simplify reassembly.
2. When disassembling, use care not to damage valve surfaces or form burrs around valve body bores.
3. When separating upper valve bodies (front and rear) from lower valve body, be careful not to lose check
balls and springs.
Inspection
1. Wash all disassembled parts and blow dry with compressed air. Inspect all valves for wear and damage,
then insert them into valve body and check that they operate smoothly while being turned.
2. Inspect valve body bore sliding surfaces for damage and wear. Check all oil holes and oil passages for
clogging.
3. Inspect all valve springs for wear, damage, excessive weakness and collapsed coils. Measure free length
of all springs and replace if incorrect.
4. Inspect valve body cover plates, and check balls for wear and damage. Check pressure relief valve for
wear and damage. Inspect oil strainer for clogging and replace if necessary.
VALVE BODY SPRING FREE LENGTH (A-41)

Application In. (mm)
Front Upper Body
Throttle Valve .864 (21.24)
Downshift Plug 1.563 (39.71)
Secondary Regulator Valve 2.946 (74.83)
Rear Upper Body
Low Coast Modulator 1.667 (42.35)
Intermediate Modulator Valve 1.008 (25.60)
Reverse Sequence Valve 1.488 (37.55)

Governor Modulator Valve 1.420 (36.07)
2-3 Shift Valve 1.382 (35.10)
Detent Regulator Valve 1.236 (31.39)
Lower Body
Reverse Sequence Valve 1.478 (37.55)
1-2 Shift Valve 1.363 (34.62)
Pressure Relief Ball 1.265 (32.14)
Check Valve 1.207 (30.65)
Primary Regulator Valve 2.887 (73.32)
Damping Ball .787 (20.00)
Fig. 28: Exploded View Of A-41 Transmission Valve Body Assembly

VALVE BODY SPRING FREE LENGTH (A-40D, A-43D & A-43DL)

Application A-40D In. (mm) A-43D & A-43DL
In. (mm)
Front Upper Body
Throttle Valve .864 (21.94) .758 (19.24)
Downshift Plug 1.563 (39.71) (1) 1.693 (43.00)
Sec. Reg. Valve 2.806 (71.27) 2.806 (71.27)

Cut-Back Valve .... (2) .906 (23.00)
Rear Upper Body

Sequence Valve 1.478 (37.55) 1.478 (37.55)
Gov. Mod. Valve 1.420 (36.07) (3) 1.420 (36.07)
2-3 Shift Valve 1.420 (36.07) (3) 1.382 (35.10)
2-3 Shift Time Valve 1.174 (29.82) .....

Det. Reg. Valve 1.198 (30.43) (3) 1.178 (29.93)
Low-Coast Mod. Valve 1.667 (42.35) (3) 1.667 (42.35)
3-2 Kick-Down Valve .991 (25.17) ....

3-4, 3-2 & 1-2 Shift Valves .... (2) 1.148 (29.15)
Lower Body
1-2 Shift Valve 1.363 (34.62) (3) 1.363 (34.62)
Pressure Relief Ball 1.265 (32.14) 1.265 (32.14)

Oil Cooler Check Valve 1.312 (33.32) 1.312 (33.32)
Prim. Reg. Valve 2.217 (56.30) (4) 2.887 (73.32)
Damping Ball .787 (20.00) .787 (20.00)

3-4 Shift Valve 1.385 (35.18) (3) 1.325 (33.65)
OD Clutch Exh. Valve 1.224 (31.09) ....

Lock-Up Relay Valve .... (2) 1.362 (35.60)
Low Coast Mod. Valve .... (2) 1.667 (42.35)
Int. Mod. Valve .... (2) 1.395 (35.43)
(1) A-43DL transmission is 1.557" (39.55 mm).
(2) A-43DL transmission only.
(3) A-43D transmission only.
(4) A-43DL transmission is 2.217" (56.30 mm).
Reassembly (A-41 Transmission)
1. Before reassembly, wash all components in fresh transmission fluid and blow them dry with compressed
air. DO NOT use waste or shop towels for drying valve body components. To reassemble lower valve
body, install reverse sequence valve (round end first) and spring.
2. Install low-coast shift valve. Set valve body on edge and carefully insert 1-2 shift control valve spring
(smaller), 1-2 shift valve and plug. Install 1-2 shift control valve plug retainer. Insert primary regulator
valve with large end first. Make sure valve fits flush with valve body.
3. Insert regulator valve plunger into sleeve with rounded end first. Plunger should be recessed inside
sleeve. Insert sleeve with plunger. Install regulator valve spring retainer. Install pressure relief ball, spring
and retainer.
4. Identify check balls and spring. Larger ball goes with spring. Install smaller check ball, spring, larger
check ball and cooler by-pass check valve. See Fig. 29 .
Fig. 29: Installing Check Balls & Check Valve (A-41 Transmission)
5. Install lower valve body and gasket. Make sure new gasket matches old gasket. Set lower valve body
plate in place. Temporarily install 2 short bolts finger tight to compress plate against spring-loaded check
valve.
NOTE: Do not confuse lower valve body gasket with upper valve body gasket. See
Fig. 30 for gasket identification.
Fig. 30: Valve Body Gasket Identification (A-41 Transmission)

6. Install throttle valve retainer. Install adjusting rings and small spring on throttle valve shaft. Make sure to
install same number of rings as were removed during disassembly. Insert spring and downshift plug.
7. Push downshift plug into valve body and temporarily install cut-back plug retainer. Assemble throttle
cam and install on upper front valve body, tightening to 53-78 INCH lbs. (6-9 N.m). See Fig. 31 . After
throttle cam is installed, pull on it to see that it turns smoothly and moves full stroke.
8. Push in downshift valve and remove temporary retainer. Make sure roller or plug follows smaller portion
of cam. Partially install cover plate and insert spring and secondary regulator valve. Compress spring and
swing cover plate into place.
Fig. 31: Installing Throttle Cam & Spring

9. Install second bolt in cover plate and tighten both bolts. Insert cut-back valve and plug with smaller end
of valve first. Install cut-back valve retainer. Install rubber check ball into position in front upper valve
body. See Fig. 32 .
10. To reassemble upper rear valve body, install detent regulator valve, spring and retainer. Insert valve with
round end first. Make sure retainer fully covers end of spring. Insert intermediate modulator valve (round
end first) and spring.
Fig. 32: Installing Front Upper Body Check Ball (A-41 Transmission)
11. Compress intermediate modulator spring and install valve body side cover with 1 bolt. Insert rear clutch
sequence valve round end first. Compress spring and rotate cover to hold it. Insert low modulator valve
(round end first) and insert spring.
12. Compress spring and swing cover over to hold it. Position cover and install second bolt. Tighten both
bolts. Insert 2-3 shift valve with smaller end first. Insert plug. Compress plug and install intermediate
shift valve retainer in valve body.
13. Insert spring and intermediate shift valve into bore. Insert valve with round end up. Insert plug and
retainer. Insert check balls. See Fig. 33 .
Fig. 33: Installing Check Balls In Rear Upper Body (A-41 Transmission)
14. To assemble valve body, position new gasket on upper rear valve body. Make sure new gasket matches
old gasket. Align gasket at lower left corner. Place lower valve body with plate on top of upper rear valve
body and align at left edge.
15. Install and finger tighten 3 bolts in lower valve body to secure upper rear valve body. Turn assembly
over, check gasket alignment and finger tighten 5 bolts in upper rear valve body. Remove temporary bolts
from plate. Place lower and upper rear valve body assembly on top of upper front valve body.
16. Install and finger tighten set bolts in lower valve body to secure upper front valve body. Turn assembly
over and finger tighten 5 bolts in upper front valve body. Recheck gasket alignment. Tighten bolts in
upper front and rear valve bodies. Turn assembly over and tighten bolts in lower valve body. Insert
manual valve and install detent spring.
Reassembly (A-40D, A-43D & A-43DL)
1. To assemble lower valve body on A-40D and A-43D, install reverse brake plug (A-40D) or sequence
valve (A-43D). Carefully insert low-coast shift valve with small end first. Insert 3-4 shift control valve
with cup side first. Insert 3rd-coast shift valve with small end first.
2. Insert inside plug with thick face first. Using tweezers, insert locating pin. Insert outside plug and locating
pin. Install cover plate. Set valve body on edge, insert spring, 1-2 shift valve (small part first) and plug.
Install 1-2 shift valve plug retainer.
3. Install spring, 3-4 shift valve and plug. Install 3-4 shift valve plug retainer (A-40D) or locating pin (A-
43D). On A-40D, insert overdrive clutch exhaust valve with round end first.
4. Insert spring and install overdrive clutch exhaust valve spring retainer. Install manual down timing valve,
small end first. Insert plug with large end first. Install manual down timing valve retainer.
5. On all models (including A-43DL), insert primary regulator valve, large end first. Insert spring. Make
sure primary regulator valve fits flush with valve body. Insert regulator valve plunger (rounded end first)
into sleeve. Plunger should be recessed inside sleeve. Insert sleeve with plunger. Install regulator valve
spring retainer.
6. On A-43DL, assemble spring, lock-up relay control valve, lock-up relay valve and plug into sleeve. Insert
sleeve into bore and install plug retainer pin. Install No. 3 solenoid and temporarily tightening bolt. Install
low-coast modulator valve and intermediate modulator valve with their springs. Install No. 1 and 2
solenoids.
7. On all models, install pressure relief ball, spring, 4 check balls (A-40D and A-43D) and retainer. See Fig.
35 and Fig. 36 . On A-40D and A-43D, install gasket, plate, gasket and lower body cover. (Gaskets are
NOT interchangeable.) On A-43DL, install 2 valve body covers, using wave washer for smaller cover.
8. On A-40D and A-43D, note 2 rubber check balls are different sizes. Spring goes with larger ball. Install
smaller check ball, spring, larger check ball and oil cooler by-pass check valve. See Fig. 37 and Fig. 38 .
On A-43DL, install damping ball, spring and cooler by-pass check valve. See Fig. 39 .
9. Install lower valve body gasket, making sure new gasket matches old gasket. Install lower valve body
plate. Set plate into place. Temporarily install 2 bolts finger tight to compress plate against check valve.
10. To reassemble upper front valve body, insert throttle valve and retainer. Install adjusting rings (same
number as removed) on throttle valve shaft. Insert spring and downshift plug.
Fig. 34: Exploded View Of A-40D & A-43D Transmission Valve Body
Fig. 35: Installing Check Balls In Lower Valve Body (A-40D Transmission)
Fig. 39: Installing Check Balls In Lower Valve Body (A-43DL Transmission)
11. Temporarily install cut-back plug retainer to hold downshift plug in place. Assemble throttle cam
assembly. Install throttle cam to upper front valve body, tightening to 53-13 INCH lbs. (6-9 N.m).
12. After throttle cam is installed, pull on it to see that it turns smoothly and moves full stroke. Push in
downshift valve and remove temporary retainer. Make sure roller or plug follows smaller portion of cam.
13. Partially install cover plate and insert spring and secondary regulator valve. Compress spring and swing
cover plate into place. Install second bolt in cover plate and tighten both bolts. Insert cut-back valve and
plug with smaller end of valve first. Install cut-back valve retainer. Install rubber check ball (except A-
43DL). See Fig. 40 .
Fig. 40: Installing Check Ball To Front Upper Valve Body

14. To reassemble upper rear body on A-40D and A-43D, install detent regulator valve with round end first.
Compress spring and install retainer over spring. On A-40D, install spring and 2-3 shift timing valve.
15. On A-43D, install intermediate modulator valve (round end first), then install spring. On A-40D and A-
43D, install valve body side cover with 1 bolt. Insert rear clutch sequence valve (round end first), then
install spring.
16. Insert governor modulator valve (round end first). Insert spring. Insert low modulator valve (round end
first), then install spring. Position cover and install second bolt. Tighten both cover bolts.
17. On A-43D, insert 2-3 shift valve (small end first) and insert plug. On A-40D, insert valve spring, and
insert kick-down orifice control valve with long bevelled end first. Install plug into bore and insert pin
into hole (coat pin with petroleum jelly). Insert 2-3 shift valve with large end first. Compress plug and
install intermediate shift valve retainer in valve body.
18. On A-40D and A-43D, insert spring and intermediate shift valve into bore. On A-40D, insert plug and
locating pin. On A-43D, insert plug and retainer. On A-40D and A-43D, install check balls as shown in
appropriate illustration. A-40D has 1 steel and 4 rubber balls, A-43D has 1 steel and 3 rubber balls.
19. To reassemble upper rear body on A-43DL, install 3-4 shift valve and spring. Install plug in bore. Coat
retainer with petroleum jelly and install. Install 1-2 shift valve and spring. Install plate over gasket. Install
2-3 shift valve and spring. Install plug in bore. Coat pin with petroleum jelly and install. Install 6 check
balls.
20. To reassemble valve body, make sure new gasket matches old and position on upper rear valve body.
Align gasket at lower left corner. Place lower valve body with plate on top of upper rear valve body.
Install and finger tighten 3 bolts in lower valve body to secure upper rear valve body.
21. Turn assembly over, check gasket alignment, and finger tighten bolts in upper rear valve body. Remove
temporary bolts from plate. Place lower and upper rear valve body assembly on top of upper front valve
body. Install and finger tighten set bolts in lower valve body to secure upper front valve body.
22. Turn assembly over and finger tighten 5 bolts in upper front valve body. Recheck alignment of gaskets
and tighten bolts in upper front and rear valve bodies. Turn assembly over and tighten bolts in lower
valve body. Insert manual valve. Install decent spring.
Fig. 41: Exploded View Of A-43DL Transmission Valve Body Assembly

GOVERNOR VALVE ASSEMBLY
Disassembly
Remove "E" ring and lift off governor weight. Remove governor valve shaft, spring and governor valve from
governor body. See Fig. 42 .
Inspection
Inspect all parts for wear and damage. Insert valve shaft into body and make sure it slides smoothly. Check oil
passage for clogging.
Reassembly
To reassemble governor valve assembly, reverse disassembly procedure.
Fig. 42: Exploded View Of Governor Assembly

TRANSMISSION REASSEMBLY
NOTE: During transmission reassembly note the following:
l Dry all parts with compressed air. Never use waste or shop towels.
l Soak new clutch discs in automatic transmission fluid for at least 2 hours
before installation.
l Apply ATF on all sliding and rotating surfaces before assembly.
l Do not use adhesive cements on gaskets and similar parts.
l Use all new "O" rings and gaskets.
NOTE: Install apply tube so lips fit into case. Ensure apply tube end lip is fitted
inside piston.
Fig. 43: Installing Brake Apply Tube

1. Place transmission case on a cylinder with front facing up. Install output shaft thrust bearing and race into
case with race lip facing down over bearing. Install brake apply tube into case. Make sure tube end lip is
completely inserted in case. See Fig. 43 .
2. Align clutch plates on output shaft. Partially insert output shaft assembly into case. On models with slot
in case, align notch in clutch plates with slot in case. Check clutch pack clearance. See CLUTCH PACK
CLEARANCE table. Measure depth of ledge below snap ring groove. See Fig. 44 . If clutch pack is not
lower than ledge, components may be misassembled or excess ATF may be on discs.
CLUTCH PACK CLEARANCE

A-40D .016-.087 (.4-2.2)
A-43DL .028-.098 (.7-2.5)
Fig. 44: Measuring Rear Brake Clutch Pack Clearance

3. Position reaction plate notch toward valve body side of case. Push plate into place. When correctly
installed, snap ring groove is completely visible. Install snap ring. Work snap ring around case. Check
that snap ring is seated and ends are between lugs. Push center support assembly into case.
4. Align oil hole and bolt hole of center support with those of body side. Align center support with holes in
case and install support bolts with wave washers finger tight. Tighten bolts alternately in small
increments. Install rear clutch to case. Rotate clutch to mesh with center support.
5. When correctly installed, splined center of clutch will be flush with end of sun gear shaft. Install needle
bearing race over splined end of rear clutch in case. Coat parts with petroleum jelly to hold in place. Place
lip of race outward.
6. Align flukes of rear clutch discs and mesh with front clutch hub. Push front clutch assembly into case,
being careful not to let thrust bearing fall out. Place a straightedge across case top surface and measure
clearance between clutch and straightedge. See FRONT CLUTCH CLEARANCE table.
FRONT CLUTCH CLEARANCE

A-41 .06 (1.5)
A-40D 1.22 (31.0)
A-43D & A-43DL .08 (2.0)
7. Install guide rods (SST09350-20013) finger tight to case. Coat thrust bearing with petroleum jelly and
install to front clutch. On all except A-41, coat thrust washer with petroleum jelly and install to overdrive
case. Lip side should face overdrive case.
8. Insert overdrive case gently through 2 guide pins. Coat thrust washers with petroleum jelly. Install 1
washer to overdrive case and 1 washer to overdrive clutch. Washer lugs should be inserted to holes. Align
flukes of discs in overdrive case.
9. Align flukes with slots of overdrive clutch and press overdrive clutch into case. Be careful that thrust
washer does not fall out. Place a straightedge across case top surface and measure clearance between
overdrive clutch and straightedge. See OVERDRIVE CLUTCH CLEARANCE table.
OVERDRIVE CLUTCH CLEARANCE

A-40D & A-43D 08(2.0)
A-43DL .14(3.5)
10. Install "O" ring on overdrive case. On all models, install converter housing and tighten bolts. Install thrust
washer and bearing on front clutch (A-41) or overdrive clutch (all others). Install thrust washer with lip
side facing outward together with bearing.
11. Install thrust washer with lip side toward pump to front oil pump. Install front oil pump gently through
guide pins. Coat 5 set bolts with liquid sealer and finger tighten them. Remove guide pins and insert 2 set
bolts coated with liquid sealer. Tighten set bolts gradually and evenly. Blow low-pressure compressed air
into passages to test accumulator piston operation. See Fig. 45 .
Fig. 45: Testing Piston Operation

12. Check input shaft and output shaft. Make sure input shaft turns and has axial play. Make sure output shaft
has thrust play in axial direction. Thrust play should be .012-.035" (.3-.9 mm). Assemble a new collar to
manual valve lever with a new roll pin.

13. Install manual valve lever shaft to transmission case through manual valve lever. Drive in new roll with
slot at right angle to shaft. Match collar hole to lever calking hollow and calk collar to lever. Install park
pawl, pivot pin and spring in case.
14. Install and tighten park pawl bracket on case, making sure collar on control rod is toward front of
transmission. Check operation of park lock pawl, making sure planetary gear output shaft is locked when
manual valve lever is in "P" range.
15. Install new "O" rings on throttle cable fitting. Install throttle cable in case, seating fully. Install
accumulator piston and springs. On A-40D, install new "O" rings to transmission case. On all models,
place valve body on transmission. Make sure accumulator pistons are pressed fully into bore.
16. Align manual valve with pin on manual shift lever. Lift side of valve body and slip throttle cable into cam
slot. Install attaching bolts for valve body. Install oil screen and bolts. Connect solenoid wiring to each
solenoid (A-43D). Install oil tubes (if equipped). Install magnet in pan and install oil pan with new gasket.
17. Install drain plug with new gasket. On all except A-43DL, lift governor body retaining clip with
screwdriver and slide governor body onto output shaft. Insert retaining clip end into hole on output shaft.
On A-43D, install lock screw and stake lock plate in place.
18. On A-43DL, install sensor rotor, putting large diameter snap ring at front. On all models, install
speedometer drive gear snap ring and lock ball on output shaft. Slide speedometer drive gear onto shaft
and install outer snap ring. Install extension housing and new gasket and tighten bolts. Install "O" rings,
bushing and speedometer driven gear to shaft sleeve.
19. Install speedometer driven gear assembly in extension housing. Insert shaft sleeve assembly into housing.
Install lock plate with bolt and lock washer. Slide neutral start switch onto control shaft. Install grommet,
facing groove toward switch body.
20. Install washer and nut. Move switch so that slit in switch and neutral base line up. Tighten bolt and nut.
Install shift handle. On all except A-43DL, install solenoid switch with 2 "O" rings.
TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS
Application Ft. Lbs. (N.m)
Center Support-To-Case Bolt 18-20 (25-27)
Converter Housing-To-Case
Short Bolt 20-30 (27-41)
Long Bolt 35-49 (48-67)
Converter-To-Drive Plate Bolt 11-15 (15-20)
Extension Housing-To-Case Bolt 20-30 (27-41)
Oil Pump-To-Case Bolt 14-18 (19-25)
Transmission-To-Engine Bolt 37-57 (50-78)
INCH Lbs. (N.m)
Lock Pawl Bracket-To-Case Bolt 52-78 (5.9-8.8)
Oil Pan-To-Case Bolt 38-43 (4.3-4.9)
Strainer-To-Valve Body Bolt 43-52 (4.9-5.9)
Test Plugs-To-Case 52-78 (5.9-8.8)
Valve Body-To-Case Bolt 69-104 (7.8-11.8)
PIN VOLTAGE TESTS
NOTE: For ECU connector pin voltages, see Fig. 46 .
Fig. 46: Cressida & Supra ECU Connector Voltage Chart

WIRING DIAGRAMS
Fig. 47: Cressida & Supra Transmission ECU Circuitry

OIL CIRCUIT DIAGRAM
Fig. 48: Toyota A-41 Automatic Transmission Hydraulic Circuit Diagram


Diagnostico y Overhaul A41 A40d Toyota Transmision

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Diagnostico y Overhaul A41 A40d Toyota Transmision

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1983 Toyota Celica GT

1983 AUTOMATIC TRANSMISSIONS

A-41, A-40D, A-43D & A-43DL Diagnosis & Overhaul

NOTE: Information is not available.

viernes, 30 de septiembre de 2016 8:32:33

Fig. 1: Transmission Electrical Components (Cressida)

Fig. 2: Transmission Electrical Components (Supra)

LUBRICATION & ADJUSTMENTS

NOTE: See appropriate SERVICING article.

NO MOVEMENT IN ANY RANGE

SHIFT LEVER POSITION INCORRECT

Manual linkage out of adjustment. Faulty manual valve and lever.

HARSH ENGAGEMENT INTO ANY DRIVE GEAR

SLIP ON ANY UPSHIFT OR SLIP OR SHUDDER ON TAKEOFF

NO DOWNSHIFT WHEN COASTING

DOWNSHIFTS TOO SOON OR TOO LATE WHEN COASTING

NO OD-3, 3-2 OR 2-1 KICKDOWN

NO ENGINE BRAKING IN "2"

VEHICLE DOES NOT HOLD IN "P"

CLUTCH & BAND APPLICATIONS

CLUTCH & BAND APPLICATIONS

Second Front Clutch & Brake No. 2

(2) Inner piston applied.

(3) Applied when engine is braking.

(4) One-way clutch No. 1 applied.

(5) Outer piston applied.

NOTE: For ECU circuitry, see Fig. 47 .

ELECTRONIC CONTROL CIRCUIT

BRAKE SIGNAL DG TERMINAL VOLTAGE

ECU Connector Voltage

Neutral Start Switch

Throttle Position Sensor

Speedometer (Analog Type)

Speedometer (Digital Type)

Pattern Selection Switch

SHIFT SPEED SPECIFICATIONS

SHIFT SPEED SPECIFICATIONS

3-2 Downshift In "D" 57-67

2-1 Downshift In "D" 26-34

3-2 Downshift In "D" 48-58

2-3 Upshift In "D" (3) 76-86

3-OD Upshift In "D" (1) 69-79

3-2 Downshift In "D" (3) 57-66

2-1 Downshift In "D" (3) 10-33

(3) At about 60 percent throttle valve opening.

HYDRAULIC PRESSURE TESTS

GOVERNOR PRESSURE SPECIFICATIONS

Fig. 3: View Of Transmission Case Showing Hydraulic Pressure Test Ports

LINE PRESSURE SPECIFICATIONS

Line Pressure Test Results

defective throttle valve, throttle cable out of adjustment, or defective OD clutch.

NOTE: DO NOT maintain stall RPM for more than 5 seconds.

STALL TEST SPECIFICATIONS

Stall Test Results

One-Way Clutch Test

REMOVAL & INSTALLATION

EXTENSION HOUSING & ROTOR SENSOR

Removal & Installation

Fig. 4: Governor Assembly Removal

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

Fig. 7: Removing Rear Parts Group

COMPONENT DISASSEMBLY & REASSEMBLY

OIL PUMP & STATOR SHAFT