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    A340 Atsg PDF

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    cartronix2010

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    © All Rights Reserved
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    TEAROOWN ...... ‘COMPONENTS OIL PUMP PLANETARY... OVERDRIVE SUPPORT . DIRECT CLUTCH (C2) ..... FORWARD CLUTCH (C1) FRONT PLANETARY SECOND BRAKE (82) FIRST & REVERSE (83) VALVE BODY .... ASSEMBLY Technical Service Information INTRODUCTION TOYOTA A-340 EH The Toyota A-340 E and A-340 H automatic overdrive unit was ‘designed for use in trucks. The unit comes with either computer controls (E) or hydraulic controls (H). This unit was introduced in 1985 vehicles. This bookiet covers teardown and assembly of both the 340 E and 340 H models. We thank Toyota Motor Company for the illustrations and information that made this booklet possible. ROBERT D. CHERRNAY DALE ENGLAND TECHNICAL DIRECTOR FIELD SERVICE CONSULTANT FRANK MIETUS. WAYNE COLONNA. TECHNICAL CONSULTANT TECHNICAL CONSULTANT WELDON BARNETT ED KRUSE. TECHNICAL CONSULTANT LAY OUT AUTOMATIC TRANSMISSION SERVICE GROUP, ‘9200 SOUTH DADELAND BLVD. SUITE 720 MIAMI, FLORIDA 33156 (305) 661-4161 Technical Service Information COMPONENTS DISASSEMBLY OF TRANSMISSION Solero Wire (aseon) ‘Speedometer Drive Ges mn Soetdorat riven Ge Poasker Speed Sensor [ERE WAT Soesited rave Bonen Technical Service Information COMPONENTS (Cont'd) en Technical Service Information COMPONENTS (Cont'd) =i) a case ring Lock Pa ________srconscoo trate Of Seat i racket (ASAOE) Parcng Lock fing fred 'a38081 ga com ores Pinon cock Pool Shatt (A408) / ——serng See 8 sering 4 creek 83 898 ston # eer eit — 9 s+ vane Boay | co 3S anu ETE) ATSGI] Technical Service Information SEPARATE BASIC SUBASSEMBLY REMOVE WIRE HARNESS CLAMP ANO THROTTLE ] Chace’ Game REMOVE CONTROL SHAFT LEVER REMOVE NEUTRAL START SWITCH la} Unstake the fock washer. (6) Remove the nut and bolts, and then remove the neutral start switch {c]_ Remove the lack washer and grommet. aa] REMOVE TWO UNIONS AUTOMATIC TRANSMISSION SERVICE GROUP Technical Service Information REMOVE THERMO SENSOR (A340) REMOVE SPEEDOMETER DRIVEN GEAR (A340E) REMOVE SPEED SENSOR (A340E) {a} Disconnect the connector, (o} Remove the speed sensor. REMOVE TRANSMISSION HOUSING (a) Remove the six bolts (bp) Remove the transmission housing, REMOVE EXTENSION HOUSING (A340E) {a} Remove the six bolts (b} Remove the extension housing and gasket. Technical Service Information INSPECT EXTENSION HOUSING BUSHING (A340E) Using a eylinder gauge, measure the inside diameter of the extension housing bushing Maximum inside diameter: 40.09 mm (1.5783 in.) If the inside diameter is greater than the maximum, replace the extension housing REMOVE SPEEDOMETER DRIVE GEAR (A340) (a) Using snap ring pliers, emave the snap ring (&) Remove the speedometer drive gear and ball REMOVE SENSOR ROTOR (A340E) la} Remove the sensor rotor and key, tb] Using snap ring pliers, eemove the snap ring REMOVE OIL PAN CAUTION: Do not turn over the transmission as this wil contaminate the valve body with foreign materials in the bottom of the pan. la} Remove the nineteen bolts Ib} Remove pan by lftipg the transmission ease. EXAMINE PARTICLES IN PAN Remove the magnet and use it to collect any steel chips Look carefully at the chips and particies in the pan and on the magnet t0 anticipate what type of wear you will find in the transmission ‘Stee! (magnetic) bearing, gear and clutch plate Brass (non-magnetic) .. bushing wear Technical Service Information (a3a0e) TURN OVER TRANSMISSION AND REMOVE OIL, STRAINER (a) Remove three bolts holding the oil strainer to the valve body, Ib) Remove the cil strainer and two gaskets. (a34on TURN OVER TRANSMISSION AND REMOVE OIL STRAINER la) Remove eleven bolts holding the lower ol strainer to the upper oil strainer. lb} Remove the lower oil strainer and gasket. (c) Remove five bolts holding the upper oil strainer to the valve body, (a) Remove the upper oll strainer and two gaskets. REMOVE OIL TUBES Pry up both tube ends with a large screwdriver and remove ‘the tubes. A340E: Two tubes A340H: Three tubes REMOVE SOLENOID WIRING [e)_ Disconnect the connectors from the No. 1, No. 2nd No, 3 solenoids. Technical Service Information {b) Turn over transmission, veimove the stopper plete from the case. (e)_ Pull the wiring out of the transmission ease REMOVE VALVE BODY {a} Remove the bolts AADE : Seventeen bolts ABAOH: Sixteen bolts (©) Disconnect the throttle eable from the cam REMOVE CHECK BALL BODY, FOUR SPRINGS AND TWO PINS. {a} Remove the check ball body and spring (0) Remove springs and two pins from sccumulator piston, ASA0E: Four sorings A340H: Three sings REMOVE ACCUMULATOR PISTONS AND SPRINGS (a) Applying compressed sir to the oil hole, remove the Band Cs accumulator pistons and two springs. 10 Technical Service Information (&} Applying compressed air 10 the oil hole, remove the Be accumulator piston end spring (2) Apelying compressed air to the oil hole, remove the (Gs accumulator piston. TURN OVER TRANSMISSION AND REMOVE THROTTLE CABLE STAND UP TRANSMISSION AND REMOVE OIL PUMP (a) Remove seven bolts holding the oll pump to the ‘vansmission case (o) Using SST, remove the oil pur. ‘SST 09350-30020 (0935007020) ul Technical Service Information —— REMOVE RACE FROM OIL PUMP REMOVE OVERORIVE PLANETARY GEAR AND OVERDRIVE DIRECT CLUTCH (a) Remove the oversrive planetary gear and overde direct eluten from thw iransisssin cose (>) Remove the race REMOVE OVERDRIVE PLANETARY RING GEAR {a} Remove the bearing and race Ib} Remove the overdrive planetary ring gear from the 12 Technical Service Information CHECK PISTON STROKE OF OVERDRIVE BRAKE [a) Place SST and 2 dial indicator onto the overdrive brake piston as shown in the figure. ‘SST 09350-30020 (09350-06120) lb} Measure the stroke applying and releising the com: rested air (4 ~ 8 kglem*, 87 ~ 114 psi or 992 ~ 785 kPa) as showa in the figure Piston stroke: ‘AR40E 1.80 — 1.70 mm (0.0561 — 0.0669 in.) AB40H 1.32 — 1162 mm (0.0520 ~ 0.0638 in.) If the values are nonstandard, replace the disc or flange REMOVE FLANGES, PLATES AND DISCS (a) Remove the snap ring, (o) Remove flanges, plates and diss. AOE: Two flanges Three plates Four discs AQKOH : Two flanges Two plates ‘Three dises DISC INSPECTION Using @ micrometer, measure the thicknesses of the diss. Minimum thickness: 1.84 mm (0.0724 in.) B Technical Service Information If thickness excoeds limits, replace it and recheck piston stroke. If piston stroke is nonstandard, select another flange NOTE: There are seven flanges. Flange tioknate mein No | Triewnes No. | Thexneee 26 | 330.190) 3s oso 2538 0.196) 28 3910158) 12 [38 (0142) Nene A187) 2 [a7 omer | = REMOVE OVERDRIVE SUPPORT ASSEMBLY (2) Remove the thrust bearing and two races. () assembly t0 the case, (fe) Using SST, remove the snap ring ‘SST 09350-30020 (08950-07060) (4). Using SST, remove the overdrive support assembly SST 09350-30020 (09350-07020) 4 Technical Service Information (e} Remove the race, CHECK PISTON STROKE OF SECOND COAST BRAKE (a). Place 2 mark on the second coast brake piston rod as showa in the figure. (b) Using SST, measure the stroke applying the com: pressed air (4 — 8 kg/em*, 87 — 114 psi or 392 ~ 785 kPa) as shown in the figure ‘SST 09240-00020 Piston stroke: 1.5 ~ 3.0 mm (0.059 — 0.118 in.) If the values are nonstandard, replace piston rod and re- check piston stroke. If piston stroke is nonstandard, replace brake band NOTE: There are two piston rods. Rod length 71.4 mm (2.811 in.) 729 mm (2.870 in.) REMOVE SECOND COAST BRAKE PISTON {a} Using SST, remove the snap ring, ‘SST 09350-30020 (03350-07080) (b) Applying compressed air to the oil hole, remove the second coast brake piston assembly. 15 DISASSEMBLE SECOND COAST BRAKE PISTON {a} Remove the Eng (b) Remove the piston, spring and retainer from the piston rod, (c) Remove the oil seal trom the piston. REMOVE DIRECT CLUTCH AND FORWARD CLUTCH (a) Remove the direct clutch and forward clutch trom the case (&) Remove the bearing and race REMOVE SECOND COAST BRAKE BAND la) Remove the E:ving from the pi. [b}) Remove the pin from the brake band (e) Remove the second coast brake band from the cate 16 Technical Service Information (6) Remove the flange, dises and plates. AG40E: One flange Five dises Five plates A4OH: One flange Four discs Four plates DISC INSPECTION Using a micrometer, measure the thicknesses of the discs, ‘Minimum thickness: 1.84 mm (0.0724 in.) 1f the thickness is less than minimum, replace the disc REMOVE PARKING LOCK ROD (2) Remove the parking lock paw! bracket. (A340E) lb) Remove the parking lock rod from the manual valve lever. REMOVE PARKING LOCK PAWL AND SHAFT (A3408) Remove the spring, parking lock pawl and shaft, v7 Technical Service Information CHECK PACK CLEARANCE OF FIRST AND REVERSE BRAKE Using a thickness gauge, measure the clearance between the plate and second brake drum as shown in the figure, Clearance: ‘ASAE 0.73 ~ 2.25 mm (0.0287 ~ 0.0886 in.) ‘A340H 0.63 — 2.03 mm (0.0248 — 0.0799 in.) 1f the values are nonstandard, replace the discs REMOVE SECOND BRAKE PISTON SLEEVE REMOVE REAR PLANETARY GEAR, SECOND BRAKE DRUM AND OUTPUT SHAFT (a) Using SST, remove the snep ring ‘SST 08350-30020 (09350-07060) {b) Remove the rear planetary gear, second brake drum and output shaft as an assembly (ec) Remove the assembled thrust bearing and race from the cate. 18 @4ATSG Technical Service Information COMPONENT GROUP DISASSEMBLY, INSPECTION AND ASSEMBLY NOTES: The instructions here are organized so that you work on only ane 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. All 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 present accidentally spraying automatic transmission fluid or kerosene in your face. PARTS ARRANGEMENT 1. After eleaning, 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- Sspection, repair and assembly of other component groups. Recommended ATF type DEXRON® I 3. The recommended automatic transmission fluid oF 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 thirty minutes before assembly. 4, If 8 worn bushing is to be replaced, the sub. assembly containing that bushing ‘must be replaced. 5. Cheek thrust bearings and races for wear or damage. Replace if necessary. 6. Use petroleum jelly to keep parts in place AUTOMATIC TRANSMISSION SERVICE GROUP Technical Service Information MANUAL VALVE LEVER AND SHAFT goin —___@_\ saa vane eve PY ¢ sec —___ Manual Valve Lever Shaft @ © 0 Sea Le Nonsesabie oat REMOVE MANUAL VALVE LEVER AND SHAFT (a) Using a chisel, cut off the spacer and remove it from the shat (b] Using 8 punch, drive out the pin {e} Pull the manual valve lever shaft our through the case by the threads. 20 Technical Service Information REMOVE OIL SEAL Using a screwdriver, remove the ol sal INSTALL NEW OIL SEAL {a} Coat 2 new oil sea lip with MP grease. (5) Using SST, drive in the oil sel. ‘SST 09350-30020 (08350-07110) INSTALL MANUAL VALVE LEVER AND SHAFT (a) Assemble 2 new spacer to the manual valve lever. (lb) Install the manual valve lever shaft to the transmis: fon cate through the manual valve lever by the threads, (6) Drive in the pin with the slot at 2 right angle to the shaft {a} Motch the spacer hole to the lever calking hollow and ccalk the spacer to the lever. (e} Make sure the manual valve lever shaft turns smooth: Wy. a Technical Service Information OIL PUMP Stator Shath 01 Seat Ring 011 Pume Body | ~00 (i Pump Driven Gear it Pump Drive Gear 04501 © Nonrevesle art ss DISASSEMBLY OF OIL PUMP. USE TORQUE CONVERTER AS WORK STAND REMOVE O-RING REMOVE TWO OIL SEAL RINGS 22 TSG Technical Service Information REMOVE STATOR SHAFT Remove the thirteen bolts, and then remove the stator shaft from the oil pump body. REMOVE OIL PUMP DRIVE GEAR AND DRIVEN GEAR INSPECTION OF OIL PUMP CHECK OIL PUMP BODY BUSHING Using a dial indicator, measure the inside diameter of the oil pump body bushing Maximum inside diameter: 38,19 mm (1.5036 in.) 1 the inside diameter is greater than the maximum, replace the oil pump body. CHECK STATOR SHAFT BUSHING Using a dial indicator, measure the inside diameter of the stator shaft bushing Maximum inside diameter: Front side 21.58 mm (0.8496 in.) Rear side 27.08 mm (1.0661 in.) If the inside diameter is greater than the maximum, replace the stator shaft, CHECK BODY CLEARANCE OF DRIVEN GEAR Push the driven gear to one side of the body. Using feeler gauge, measure the clearence. 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, re the drive gear, driven gear or pump body. 23 Technical Service Information CHECK TIP CLEARANCE OF BOTH GEARS Measure between the gear teeth and the eresent shaped part of the pump body. ‘Standard tip clearance: 0.11 —0.18 mm (0.0043 ~ 0.0058 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 oF pump body. CHECK SIDE CLEARANCE OF BOTH GEARS Using 2 steel straightedge and a fesler gauge, measure the fide 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. CHECK OIL SEAL, ‘Check for wear, damage or cracks. IF NECESSARY, REPLACE OIL SEAL (a) Pry off the oi seal with a serewdriver (b) Using SST, install 2 new oi! seal The oil seal end should be flush with the outer edge (of the pump body. SST 09350-30020 (09351-32140) (e) Coat the oil seat tip with MP grease. 24 TSG Technical Service Information ASSEMBLY OF OIL PUMP INSTALL DRIVEN GEAR AND DRIVE GEAR TO OIL PUMP BODY (a). Place the oil pump body on the torque converter. (©) Coat the driven gear and drive gear with ATF, (e)_ Install the driven gear and drive gor. INSTALL STATOR SHAFT TO OIL PUMP BODY (a) Align the stator shaft with each bolt holes. (0) Tighten the thirteen bolts, Torque: 100 kgem (7 fb, 10 Nm) INSTALL TWO OIL SEAL RINGS (a) Coat the il seal rings with ATF. (b} Contract the oll seal rings as shown, and install them ‘onto the stator shaft. CAUTION: Do not spread the ring ends too much INSTALL NEW O-RING Coat 8 new O-ring with ATF and install i to the ail pump body. CHECK OIL PUMP DRIVE GEAR ROTATION Make sure the drive gear rotates smoothly when installed to the torque conve Technical Service Information OVERDRIVE PLANETARY GEAR AND OVERDRIVE DIRECT CLUTCH (Co) an Ream (00 Bier Cyten Paton SP Cc UD Shap Ring an Tear ‘AS4OE onty ne-nay Clutch Bote Race Bearing (00 Paaneary Ring Gest DISASSEMBLY OF OVERDRIVE PLANETARY GEAR AND OVERDRIVE DIRECT CLUTCH CHECK OPERATION OF ONE-WAY CLUTCH Hold the OD direct clutch drum and turn the input shaft The input shatt should turn freely clockwise and should lock counterclockwise, REMOVE OVERDRIVE DIRECT CLUTCH ASSEMBLY FROM OVERDRIVE PLANETARY GEAR Technical Service Information REMOVE ASSEMBLED BEARING AND RACE FROM Sp OVERDRIVE DIRECT CLUTCH CHECK PISTON STROKE OF OVERDRIVE DIRECT CLUTCH (Ce) {a} Place the oil pump onto the torque converter, and then place the OD direct clutch assembly onto the oil pume (b) Using 2 ala! indicator, measure the overdrive direct clutch piston stroke applying and releasing the com: pressed air (4 — 8 kglem?, 57 — 114 psi or 392 — 785 kPa) as shown, Piston stroke: ‘ASA0E 1.40 — 1.70 mm (0.0551 ~ 0.0669 in.) A34OH 1.77 — 2.07 mm (0.0697 — 0.0815 in.) REMOVE SNAP RING FROM CLUTCH DRUM REMOVE FLANGE, DISCS AND PLATES NOTE: A340E — Two discs and two plates A34OH — One digo and one plate COMPRESS PISTON RETURN SPRING AND REMOVE SNAP RING Place SST on the spring retainer and compress the return spring with 2 shop press. Using snap ring pliers, remove the snap ring SST 09350-30020 (09350-07040) REMOVE PISTON RETURN SPRING ar Technical Service Information REMOVE OVERDRIVE DIRECT CLUTCH PISTON {a} Place the oi! pump onto the torque converter and ‘then place the OD direct clutch onto the oil pump. (0) Hold the OD direct clutch piston by hand, apply compressed sir to the oil pump to remove the OD direct clutch piston, fc} Remove the OD direct clutch piston, REMOVE TWO O-RINGS FROM PISTON REMOVE BEARING AND RACE FROM OVERDRIVE PLANETARY RING GEAR REMOVE SNAP RING REMOVE RING GEAR FLANGE REMOVE RACE FROM OVERDRIVE PLANETARY GEAR 28 Technical Service Information REMOVE SNAP RING REMOVE RETAINING PLATE REMOVE OVERDRIVE ONEWAY CLUTCH WITH OUTER RACE REMOVE THRUST WASHER REMOVE ONE-WAY CLUTCH FROM OUTER RACE 29 Technical Service Information INSPECTION OF OVERDRIVE PLANETARY GEAR AND OVERDRIVE DIRECT CLUTCH CHECK Discs Using micrometer, measure the thickness of the discs. Minimum thickness: 1.84 mm (0.0724 in.) If the thickness js less than the minimum, replace the disc CHECK PISTON RETURN SPRING Using calipers, measure the fee length of the return spring. ‘Standard length: 15.8 mm (0.622 in.) 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 iow pressure compressed air. CHECK OVERDRIVE DIRECT CLUTCH DRUM BUSHINGS Using 2 dial indicator, measure the inside giameter of the clutch drum bushings, Maximum inside diameter: 27.11 mm (1.0673 in.) If the inside diameter is greater than the maximum, replace the clutch drum, CHECK OVERDRIVE PLANETARY GEAR BUSHING Using a dial indicator, measure the inside diameter of the planetary gear bushing, Maximum inside diameter: 11.27 mm (0.4437 in.) If the inside diameter is greater than the maximum, replace the planetary gear 30 Technical Service Information Front t Flanged Side ASSEMBLY OF OVERDRIVE PLANETARY GEAR AND OVERDRIVE DIRECT CLUTCH INSTALL THRUST WASHER TO OVERDRIVE PLANETARY GEAR Install the thrust washer to the overdrive planetary gear, facing the grooved side upward. INSTALL OVERDRIVE ONE-WAY CLUTCH TO OUTER RACE Install the one-way clutch into the outer race, facing the flanged side of the one-way clutch upward, INSTALL OVERDRIVE ONE-WAY CLUTCH WITH OUTER RACE TO OVERDRIVE PLANETARY GEAR INSTALL RETAINING PLATE INSTALL SNAP RING 31 Technical Service Information INSTALL RACE Coat the race with petroleum jelly and install it to the planetary gear NOTE: Race diameter Inside diameter 27.1 mm (1,087 in.) Gutsise diameter 41.8 mm (1.646 in) INSTALL RING GEAR FLANGE TO OVERDRIVE PLANETARY RING GEAR INSTALL SNAP RING INSTALL RACE AND BEARING Coat the race and bearing with petroleum jelly and install them onto the planetary ring gear NOTE: Race and bearing diameter tin “ ae ue Rave 222 085) a8 (1882) [380 02a we 188 INSTALL NEW O-RINGS ON OVERDRIVE DIRECT CLUTCH PISTON Coat new O-rings with ATF and install them on the OD direct clutch piston. INSTALL OVERDRIVE DIRECT CLUTCH PISTON TO OVERDRIVE DIRECT CLUTCH DRUM Being careful nat to damage the O-rings, press inthe divect clutch piston into the eluten drum by Both hands. 32 Technical Service Information 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 2 shop press ‘SST 09350-30020 (09350-07040) {b) Install the snap cing with snap ring pliers. Be sure ‘the end gap of the snap ring is not aligned with the spring retainer claw. INSTALL PLATES AND DISCS Install in order: ASAE — P-0~ ‘A340H— PO . INSTALL FLANGE Install the flange, facing the flat end downward, INSTALL SNAP RING 33 Technical Service Information CHECK PISTON STROKE OF OVERDRIVE DIRECT CLUTCH (C2) (a) Place the oil pump onto the torque converter, and then place the OD direct clutch assemoly onto the oil pump. (b} Using a dial indicator, measure the overdrive direct cluten piston stroke applying and releasing the com- pressed air (4 ~ 8 kglom®, 57 — 114 psi or 392 ~ 785 kPa) as shown. Piston stroke: ‘A340E 1.40 ~ 1.70 mm (0.0551 ~ 0.0668 in.) ‘A340H 1.77 ~ 2.07 mm (0.0697 ~ 0.0818 in) If the piston stroke is not within specification, replace the ciscs and recheck the piston stroke. If the piston stroke is nonstandard, select enother flange. NOTE: There are six flanges. Fane ticks min) No] Thieinew [No hike 1] 38 wai 8 | Ea Ge wi 3s iorsa [20 | 1261 i I reat 31 07 INSTALL ASSEMBLED BEARING AND RACE Coat the assembled bearing and race with petroleum jelly and install it facing the race side downward. NOTE: Assembied bearing and race. lnside diameter 26.9 mm (1.738 in.) Outsige diameter 50,2 mm (1.978 in.) INSTALL OVERDRIVE DIRECT CLUTCH ASSEMBLY {2} Align the flukes of discs in the direct clutch (0) Install the direct clutch assembly onto the OD planetery gear CHECK OPERATION OF ONE-WAY CLUTCH Hold the OD itect eluteh drum and turn the input shaft ‘Tre input shaft should turn freely clockwise and should lack counterclockwise. 4 Technical Service Information OVERDRIVE SUPPORT 00 support | 0908 DISASSEMBLY OF OVERDRIVE SUPPORT ASSEMBLY CHECK OVERDRIVE BRAKE PISTON fa) Place the OD support assembly onto the direct clutch assembly. (b) Apply compressed alr into the oil passage as shown, fand be sure that the OD brake piston moves smooth Wy. 35 Technical Service Information REMOVE BEARING AND RACES (a) Remove the two races and bearing trom the OD support. (bo) Turn over the OD support, remove the rece. REMOVE CLUTCH DRUM THRUST WASHER FROM OVERDRIVE SUPPORT COMPRESS PISTON RETURN SPRING AND REMOVE SNAP RING {a} Place SST on the spring eetainer, return spring with a shop press. ‘SST 09350-30020 (08350-07030) (b} Remove the snap cing witha serewdriver REMOVE PISTON RETURN SPRING 1nd compress the REMOVE OVERDRIVE BRAKE PISTON [a Place the OD support onto the direct clutch assembly. 36 Technical Service Information (0) Hold the OD brake piston so it is not slanted and apply compressed air into the passage to remove the (OD brake piston, (c)_ Remove the OD brake piston, REMOVE O-RINGS FROM OVERDRIVE BRAKE { PISTON REMOVE TWO OIL SEAL RINGS INSPECTION OF OVERDRIVE SUPPORT CHECK PISTON RETURN SPRING Using calipers, meature the free length of the return spring ‘Standard length: 18.6 mm (0.732 in.) ASSEMBLY OF OVERDRIVE SUPPORT INSTALL TWO OIL SEAL RINGS (a) Coat the two oll sea rings with ATF. (6) Contract the oil seals as shown, and install therm onto the OD support, CAUTION: Do not spread the ring ends more than necessary. INSTALL NEW O-RINGS ON OVERDRIVE BRAKE PISTON Coat two new O-rings with ATF and install them on the (0D brake piston. INSTALL OVERDRIVE BRAKE PISTON Being careful not to damage the O-rings, press in the brake piston into the OD support by both hands, 37 Technical Service Information INSTALL PISTON RETURN SPRING tonto the OD suppor. the OD support. INSTALL RACE 0D support. NOTE: Race diameter Inside diameter 96.2 mm (1.426 in.) Outside ciameter 50.4 mm (7.984 in.) RACES AND BEARING onto the OD support NOTE: Race and bearing diameter INSTALL CLUTCH DRUM THRUST WASHER Cost the thrust washer with petroleum jelly and install it NOTE: Make sure that the lug shapes match the hole on Cost the race with petroleum jelly, and install it onto the TURN OVER OVERDRIVE SUPPORT, INSTALL Coat the two races with petroleum jelly, and install them [ Trae [ Face (A) Bor jae] are 88a) Bearing 32711267) a7 1.878) Race 18) 343 (1380) | a8 CHECK OVERDRIVE BRAKE PISTON assembly. (2). Place the OD support assembly onto the direct clutch Technica geet CLUTCH Tea) Goring —_Cleeh Dram Thrust Washer Dic Caen bison Reva Pension . a9 i Ring SHOE only DISASSEMBLY OF DIRECT CLUTCH REMOVE DIRECT CLUTCH ORUM ASSEMBLY FROM. FORWARD CLUTCH ASSEMBLY REMOVE CLUTCH DRUM THRUST WASHER FROM DIRECT CLUTCH ASSEMBLY 39 Technical Service Information CHECK PISTON STROKE OF DIRECT CLUTCH (C:) (a) Place the direct clutch assembly onto the 00 support assembly. (0) Using 2 dial indicator, measure the direct clutch piston stroke applying and releasing the compressed air (4 — 8 kglem?, 57 — 114 psi or 392 ~ 785 kPa) 85 shown, Piston stroke: A34E 1.37 ~ 1.67 mm (0.0539 — 0.0657 in.) ‘A340H 1103 — 1.33 mm (0.0406 — 0.0524 in.) REMOVE SNAP RING FROM CLUTCH DRUM REMOVE FLANGE, DISCS AND PLATES NOTE: AS40E — Four discs and four plates ‘ABAOH — Three discs and theee plates COMPRESS PISTON RETURN SPRING AND REMOVE SNAP RING Place SST on the soring retainer and compress the return spring with a shop press. Using snap ring pliers, remove the snap ring ‘SST 09350-30020 (09350-07040) REMOVE PISTON RETURN SPRING REMOVE DIRECT CLUTCH PISTON (a) Place the direct clutch drum onto the OD support (6) Hold the direct clutch piston by hand, apply com pressed air to the OD support to remove the direct clutch piston! |e) Remove the direct clutch piston. REMOVE TWO O-RINGS FROM PISTON 40 Technical Service Information [INSPECTION OF DIRECT CLUTCH | cHeck oises | Using a micrometer, measure the thickness of the discs. | Minimum thickness: 1.84 mm (0.0724 in.) a If the thickness is less than the minimum, replace the disc sce Piston RETURN SPRING _l Using calipers, measure the free length of the return spring. Standard length: 19.8 mm (0.780 in.) \ Soring Retainer CHECK DIRECT CLUTCH PISTON (a) Check that check ball is free by shaking the piston (o) Check that the valve does not leak by applying low: pressure compressed air. CHECK DIRECT CLUTCH DRUM BUSHING Using a dial indicator, measure the inside diameter of the clutch drum bushing. ‘Maximum inside diameter: §3.87 mm (2.1248 in.) If the inside diameter is greater than the maximum, replace ‘the clutch drum. AUTOMATIC TRANSMISSION SERVICE GROUP a1 Technical Service Information INSTALL SNAP RING Install the snap ring with 2 screwdriver. Be sure the end 9p of the snap ring isnot aligned with the cutout partion Of the direct clutch drum. (CHECK PISTON STROKE OF DIRECT CLUTCH (C:) (a) Place the direct clutch assembly onto the OD support assembly. (b} Using a dial ingiestor, measure the direct clutch piston stroke applying and releasing the compressed. air (4 — 8 kglem?, 87 — 114 psi or 302 — 785 kPa) as shown, Piston stro ‘ASAE 1.37 — 1.67 mm (0.0539 ~ 0.0657) ‘A340H 1.03 — 1.33 mm (0.0406 — 0.0524) If the piston stroke is not within specification, replace the discs and recheck the piston stroke I the piston stroke is nonstandard, select anather flange. NOTE: There are seven flanges. Fange tikes 0 in) We Thakoen [No | Wek 7] 30 one [3] 34 wr08 eo] srw [2] 35 018 s | a2 ore) 1] 38 @raa) @ [33 010 | INSTALL CLUTCH DRUM THRUST WASHER Cost the thrust washer with petroleum jelly and install it onto the direct clutch NOTE: Make sure thet the lugs shape match the cutout Portions on the direct clutch INSTALL DIRECT CLUTCH ASSEMBLY (a) Align the flukes of diss in the direct clutch (6) Install the direct clutch assembly onto the forward cluteh assembly, (c) Check that the distance from the direct clutch end 10 the forward clutch end should be 71.2 mm (2.803 ind. 42 Technical Service Information ASSEMBLY OF DIRECT CLUTCH INSTALL NEW O-RINGS ON DIRECT CLUTCH PISTON Coat new O-rings with ATF and install them on the direct clutch piston, INSTALL DIRECT CLUTCH PISTON TO DIRECT CLUTCH DAUM Being careful not to damage the O-rings, press in the direct clutzn piston into the eluteh drum by both hands, 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 09350-30020 (09350-07040) (b} Install the snap ring with snap ring pliers. Be sure ‘the end gap of the snap ring is not aligned with the spring retainer claw. INSTALL PLATES AND DISCS Install in order: AG40E — P-D-P-0-~P-D—P-D ‘A340 P—D-P-0-P—D INSTALL FLANGE Install the flange, facing the flat end downward. 43 Bearing 0 Seat Ring | 4 Non-reusabe part Technical Service Information FORWARD CLUTCH (C1) 8 4 | Peston Return Soring \ 2A” rorward Catch Paton ASHOE only Ccusnon Pate | DISASSEMBLY OF FORWARD CLUTCH REMOVE FORWARD CLUTCH ASSEMBLY FROM DIRECT CLUTCH ASSEMBLY REMOVE BEARING AND RACE (a) Place wooden blocks, ete. to prevent forward clutch shaft from touching the work stand, and place the 00 support on them. (b} Place the forward clutch onto the OD support and remove the bearing and race, 4 Technical Service Information CHECK PISTON STROKE OF FORWARD CLUTCH (Ci) Using a dial indicator, measure the forward clutch piston stroke applying and releasing the compressed air (4 — 8 kglem?, 57 ~ 114 psi or 392 ~ 785 kPa) as shown, Piston stroke: ‘ASAE 3.06 — 387 mm (0.1205 ~ 0.1524 in.) A340H 2.75 — 3.83 mm (0.1083 — 0.1390 in.) REMOVE SNAP RING FROM CLUTCH DRUM REMOVE FLANGE, DISCS AND PLATES NOTE: A240 — Five discs and five plates ‘AB40H — Four dises and four plates REMOVE CUSHION PLATE COMPRESS PISTON RETURN SPRING AND REMOVE SNAP RING Place SST on the spring retainer and compress the return spring with 2 shop press. Using snap ring pliers, remove ‘the snap ring ‘SST 09360-30020 (09350-07040) REMOVE PISTON RETURN SPRING REMOVE FORWARD CLUTCH PISTON (a} Place the forward clutch drum onto the OD support. (b) Hold the forward clutch piston by hand, apply com pressed air to the OD support to remove the forward lutch piston, (e) Remove the forward clutch piston, REMOVE TWO O-RINGS FROM PISTON 45 Technical Service Information REMOVE O-RING FROM FORWARD CLUTCH DRUM REMOVE THREE OIL SEAL RINGS REMOVE ASSEMBLED BEARING AND RACE INSPECTION OF FORWARD CLUTCH CHECK Discs Using a micrometer, measure the thicknesses of the discs. Minimum thickness: 1.84 mm (0.0726 in.) SS 7 I the thickness is les than the minimum, replace the disc CHECK PISTON RETURN SPRING Using calipers, measure the free length of the return spring Standard length: 11.85 mm (0.4847 in.) 46 Technical Service Information CHECK FORWARD CLUTCH PISTON (a) Check that check ball is tree by shaking the piston. (b} Check that the valve does not leak by applying low: pressure compressed ar. CHECK FORWARD CLUTCH DRUM BUSHING Using a dial indicator, measure the inside diameter of the forward clutch drum bushing, ‘Maximum inside diameter: 24,08 mm (0.9480 in.) If the inside diameter is greater than the maximum, replace ‘the forward clutch drum, ASSEMBLY OF FORWARD CLUTCH INSTALL ASSEMBLED BEARING AND RACE Cost the assembled bearing and race with petroleum jelly {and install it onto the forward clutch drum facing the race sige downward, NOTE: Assembled bearing and race Inside diameter: 33.6 mm (1.323 in.) Qutside diameter: 47.8 mm (1.882 in) INSTALL THREE OIL SEAL RINGS (a) Cost the three oil seal rings with ATF, (o) Contract the oll seal rings as shown, and install them onto the forward clutch drum. CAUTION: Do not spread the ting ends more than necessary. INSTALL NEW O-RING TO FORWARD CLUTCH RUM Coat # new Outing with ATF and install it on the forward clutch drum. INSTALL NEW O-RINGS TO FORWARD CLUTCH PISTON Coat new O-rings with ATF and install them on the for: ‘ward clutch piston 47 Technical Service Information INSTALL FORWARD CLUTCH PISTON Being careful not to damage the O-rings, press the clutch piston into the forward cluteh drum, INSTALL PISTON RETURN SPRING COMPRESS PISTON RETURN SPRING AND INSTALL SNAP RING IN GROOVE {2}, Place SST on the spring retainer, and compress the return spring with shop press, ‘SST 09350-30020 (08350.07040) (b) Install the snap ring with snap ring pliers. Be sure the end gap of the snap ring is not aligned with the spring retainer claw. INSTALL CUSHION PLATE ROUNDED END DOWN AS SHOWN INSTALL DISCS, PLATES AND FLANGE {a} Install in order: A340 — P-D-P-D-P-D-P-D-P-D A340H— P=0-P-D-P-D-P-O {b} And then install the flange facing the rounded edge Sownward. 48 Technical Service Information INSTALL SNAP RING Install the snap ring with a screwdriver, Be sure the end gap of the snap ring i not aligned with the cutout portion Of the forward eluteh drum: CHECK PISTON STROKE OF FORWARD CLUTCH (C1) Using @ dial indicator, measure the forward clutch piston stroke applying and releasing the compressed air (4 — 8 kglem?, 57 ~ 114 psi or 392 ~ 785 kPa) as shown. Piston stroke ‘A3AQE 3.06 ~ 3.87 mm (0.1205 — 0.1524 in.) ‘A340H 2.75 — 3.53 mm (0.1083 — 0.1390 in.) It the piston stroke is not within specification, replace the dises, and recheek the piston stroke. INSTALL RACE AND BEARING Gost the race and bearing with petroleum jelly, and install ‘them onto the forward eluteh drum. NOTE: Race and bearing diameter som tin Tree Ouiice Face 260 11.024) a9 (195) [Bearing | 280 11.024) 3671839) INSTALL DIRECT CLUTCH ASSEMBLY TO FORWARD CLUTCH ASSEMBLY (a) Align the flukes of dics in the direct clutch, (o} Install the direct eluteh assembly onto the forward cluten assembly, (c) Check that the distance from the direct clutch end to the forward clutch end should be 71.2 mm (2.803, in 49 ATSG Technical Service Information FRONT PLANETARY GEAR Front Planetary Ring Gest ace Bearing DISASSEMBLY OF FRONT PLANETARY GEAR REMOVE BEARING AND RACES FROM FRONT PLANETARY RING GEAR la} Remeve the race from the front planetary ting gear front side. lb) Turn over planetary ring gear, remove the bearing and REMOVE RACE FROM FRONT PLANETARY GEAR TURN OVER PLANETARY GEAR ANO REMOVE ——™~ BEARING AND RACE 50 Technical Service Information INSPECTION OF FRONT PLANETARY GEAR CHECK FRONT PLANETARY RING GEAR BUSHING Using @ dial indicator, measure the inside aiameter of the planetary ring gear bushing ‘Maximum inside diameter: 24,08 mm (0.9480 in.) IH the inside diameter is greater than the maximum, replace the planetary ring gear ASSEMBLY OF FRONT PLANETARY GEAR INSTALL RACES AND BEARING FRONT PLANETARY GEAR (a) Coat the races and bearing with petroleum jelly. (bp) install the race and bearing to the rear side of the planetary gear. f le) Turn over the planetary gear and install the race, | Make sure that the shape of the lugs match the holes | ‘on the planetary gear. | NOTE: Bearing and races diameter. mind Trae Ouse Bearing 358 306) | 7878) Face (A) 37 naa) ae ara ce (8) 343.11.380) 478 (662) INSTALL RACES AND BEARING TO FRONT PLANETARY RING GEAR (a) Coat the races and bearing with petroleum jelly (b}_ Install the race and bearing onto the rear side of the planetary ring gear. | (6) Turn over the planetary ring gear and install the rece ‘onto the front side of the planetary ring gear. NOTE: Races and bearing diameter me tind Taide ‘Gonide ‘ace (A) 308 11.201) 536 (2110) | Beasng 326 11.289), 477 (1.878) see (8) 255 (1.043) 47.0 (1.850) 51 Technical Service Information PLANETARY SUN GEAR AND NO.1 ONE-WAY CLUTCH 3 Asambied No.! One-nay ith ana Second Breve Planetary Sun Gear Seap Rog Snap Ring i Sea Ring | Sun Gear Input Oram DISASSEMBLY OF PLANETARY SUN GEAR | AND NO.1 ONE-WAY CLUTCH CHECK OPERATION OF NO.1 ONE-WAY CLUTCH Hold the planetary sun gear and turn the second brake hub. The second brake hub should turn freely clockwise and should lock counterclockwise. REMOVE ASSEMBLED NO. 1 ONE-WAY CLUTCH AND SECOND BRAKE HUS 52 ATSG Technical Service Information INSPECTION OF PLANETARY SUN GEAR AND. NO.1 ONE-WAY CLUTCH CHECK PLANETARY SUN GEAR BUSHING Uzing @ cial indicator, meature the inside diameter of the planetary sun gear Bushing Maximum inside diameter: 27.08 mm (1.0661 in.) If the inside diameter is greater than the maximum, replace the planetary sun gear. ASSEMBLY OF PLANETARY SUN GEAR AND NO.1 ONE-WAY CLUTCH INSTALL SNAP RING TO PLANETARY SUN GEAR INSTALL THRUST WASHER NOTE: Make sure that the lugs match the shape of the holes on the sun gear input drum, INSTALL ASSEMBLED NO. 1 ONE.WAY CLUTCH AND, SECOND SRAKE HUB ONTO PLANETARY SUN GEAR AS SHOWN CHECK OPERATION OF NO.1 ONE-WAY CLUTCH Hold the planetary sun gear and turn the second brake hub. The second brake hub should tuen freely clockwise and should lock counterclockwise. 53 ATSG Technical Service Information SECOND BRAKE (Bz) Paton Return Spring Soring Retainer | 9908 wa Soap Rng ‘Thrust wasn Saou an | Second Brake Paton Piston Sieve | © Noneuble pat Ee ~__] DISASSEMBLY OF SECOND BRAKE REMOVE SECOND BRAKE ASSEMBLY FROM — OUTPUT SHAFT ae. | | alt \ aS irc REMOVE THRUST WASHER, 54 Technical Service Information COMPRESS PISTON RETURN SPRING AND REMOVE SNAP RING {a} Place SST on the spring retainer, and compress the return spring with @ shop press, ‘SST 09350-30020 (09360-07040) {b) Remove the snap ring with snap ring piers. REMOVE SPRING RETAINER REMOVE PISTON RETURN SPRING REMOVE SECOND BRAKE PISTON (a) Hold the second brake piston by hand, apply com pressed air to the second brake drum to remove the second brake piston. (b} Remove the second brake piston, REMOVE O-RINGS FROM SECOND BRAKE PISTON INSPECTION OF SECOND BRAKE CHECK PISTON RETURN SPRING Using calipers, measure the free length of the return spring Standard length: 15.05 mm (0.5925 in.) ASSEMBLY OF SECOND BRAKE INSTALL NEW O-RINGS TO SECOND BRAKE PISTON Coat new O-rings with ATF and install them on the second brake piston. INSTALL SECOND BRAKE PISTON Being careful not to damage the O-rings, press in the second brake piston into the second brake drum. 55 Technical Service Information INSTALL PISTON RETURN SPRING INSTALL SPRING RETAINER COMPRESS PISTON RETURN SPRING AND INSTALL, SNAP RING IN GROOVE (a), Place SST on the spring retainer, and compress the return spring with @ shop press. ‘SST 09350-30020 (09350-07040) (b) Install the snap ring with snap ring pliers. Be sure the end gap of the snap ring is not aligned with the spring retainer claw. CHECK SECOND BRAKE PISTON MOVING Make sure the second brake piston moves smoothly when applying and releasing the low compressed air to the second Brake drum. INSTALL THRUST WASHER. Goat the thrust washer with petroleum jelly and install it. NOTE: Make sure that the cutout portions of thrust washers match teeth of the spring retainer. INSTALL SECOND BRAKE ASSEMBLY TO OUTPUT SHAFT 56 TSG Technical Service Information REAR PLANETARY GEAR AND OUTPUT SHAFT second Brake Assembly Cte ear Planetary Goat | 1st 8 Rev. Brake Pack No.1 Thrust Waser soy? No.2 Thrust Wosner ® say Clten Inner Race | 4 eg | ear Planetary Ring Gear 3990 9 0 Fog Geer Fangs" 01 eat Ring DISASSEMBLY OF REAR PLANETARY GEAR AND OUTPUT SHAFT REMOVE SECOND BRAKE ASSEMBLY FROM OUTPUT SHAFT REMOVE OUTPUT SHAFT FROM REAR PLANETARY GEAR ASSEMBLY 57 Technical Service Information REMOVE OIL SEAL RING FROM OUTPUT SHAFT REMOVE FIRST AND REVERSE BRAKE DISCS, PLATES AND FLANGE NOTE: A34OE — Six discs and six plates ‘A340H — Five discs and five plates REMOVE REAR PLANETARY GEAR FROM REAR, PLANETARY RING GEAR CHECK OPERATION OF NO.2 ONE-WAY CLUTCH Hold the planetary gear and turn the oneway clutch inner race. The oneway clutch inner race should turn freely ‘counterclockwise and should lack clockwise REMOVE NO.2 ONE-WAY CLUTCH {a} Remove the oneway clutch inner race from the rear planetary gear 58 Technical Service Information {b) Remove the snap ring with a screwdriver. {c} Remove the No.2 oneway clutch with retainers from the planetary gear. REMOVE NO.2 AND NO.1 THRUST WASHERS REMOVE RACES AND BEARING FROM REAR PLANETARY RING GEAR REMOVE SNAP RING FROM REAR PLANETARY RING GEAR 59 TSG Technical Service Information a REMOVE RING GEAR FLANGE ASSEMBLY OF REAR PLANETARY GEAR. AND OUTPUT SHAFT INSTALL RING GEAR FLANGE INSTALL SNAP RING INSTALL RACES AND SEARING ‘Cost the races and bearing with petroleum jelly, nd install them onto the rear planetary cing gear NOTE: Races and beating diameter sme tind rr ee eo) Ree | BO ase | ARB 70) Bearing 308 (1.188) 411.780) Race (@) | 276 11087) waa 768) | INSTALL NO.1 AND NO.2 THRUST WASHERS (a) Coat the thrust washers with petroleum jelly (bo) Install the theust washers onto both sides of the rear planetary gear. NOTE: Make sure that the lugs match the shape of the cutout portions en the rear planetary gear. INSTALL NO.2 ONE-WAY CLUTCH Install the one-way clutch with retainers facing the flanged side of the oneway clutch upward onto the rear planetary ear. 60 Technical Service Information T 7 INSTALL SNAP RING WHILE TURNING COUNTERCLOCKWISE, INSTALL ONE-WAY CLUTCH INNER RACE TO REAR PLANETARY GEAR CHECK OPERATION OF NO.2 ONE-WAY CLUTCH Lock Hold the planetary gear and turn the oneway clutch inner face. The one-way clutch inner race should turn freely a Counterclockwise and should lock clockwise INSTALL REAR PLANETARY GEAR ONTO REAR PLANETARY RING GEAR INSTALL FLANGE, DISCS AND PLATES (a) Install the flange facing the rounded edge downward, {o) Install in order: 61 Technical Service Information FIRST AND REVERSE BRAKE (Bs) Dike No.1 198 & Rev Brake sen Pirton Return Na. 2 1st & Re, ring Brake Paton Shap Ring Actembies Avscton Sleeve Trarsmsion Cae DISASSEMBLY OF FIRST AND REVERSE BRAKE REMOVE ASSEMBLED BEARING AND RACE FROM ‘TRANSMISSION CASE CHECK FIRST AND REVERSE BRAKE PISTON MOVING ‘Make sure the first and reverse brake piston moves smooth ly when applying and releasing the compressed ai into the transmission case, 62 Technical Service Information COMPRESS PISTON RETURN SPRING AND REMOVE SNAP RING (a). Set SST on the spring retbiner, and compress the return spring with a shop press. SST 09350-30020 (08360-07050) (©) Remove the snap ring with snap ring plies. REMOVE PISTON RETURN SPRING REMOVE NO.2 FIRST AND REVERSE BRAKE PISTON (a) Hold the No. 2 first and reverse brake piston by hand, ‘apply compressed air to the transmission case to Femove the No. 2 first and reverse brake piston. (b} Remove the No. 2 first and reverse brake piston. If the piston does not pop out with compressed air lift the piston out with needie-nose pliers. REMOVE REACTION SLEEVE Ingert SST behind the reaction sleeve and gradually lift it ‘Out of the transmission case. ‘SST 09350-30020 (09360-07080) REMOVE NO.1 FIRST AND REVERSE BRAKE PISTON Ingert SST behind the No. 1 brake piston and gradually lift it our of the transmission case ‘SST 09350-30020 (09350-07090) REMOVE SECOND BRAKE FROM OUTPUT SHAFT 63 Technical Service Information REMOVE DISCS, PLATES AND FLANGE FROM OUTPUT SHAFT NOTE: A340 — Six discs and six plates ‘A340H — Five discs and five plates ~ INSPECTION OF FIRST AND REVERSE BRAKE | CHECK DISCS Using a micrometer, measure the thicknesses of the discs Minimum thickness; 1.51 mm (0.0594 in.) If the thickness is fess than the minimum, replace the disc. T / y / CHECK PISTON RETURN SPRING Using calipers, measure the free length of the return spring ‘Standard length: 13.09 mm (0.5154 in. ASSEMBLY OF FIRST AND REVERSE BRAKE INSTALL FLANGE, DISCS AND PLATES {2} Install the flange facing the rounded edge first. (0) Install in order: A3d0E ‘A340H — INSTALL SECOND BRAKE TO OUTPUT SHAFT 64 Technical Service Information ASSEMBLE NO.1 FIRST AND REVERSE BRAKE PISTON (a) Coat three new O-rings with ATF. (6) Insta the two O-rings on the No. 1 piston. (6) Install the O-ring on the reaction sleeve, {4} Install the No, 1 piston to the reaction sleeve, INSTALL NO.1 FIRST AND REVERSE BRAKE PISTON WITH REACTION SLEEVE TO NO.2 FIRST AND REVERSE BRAKE PISTON (a) Coat a new Orting with ATE and install it on the No. 2 piston. {b) Install the No, 1 piston with reaction sleeve onto the No. 2 piston. INSTALL NO.2 WITH _NO.1 FIRST AND REVERSE BRAKE PISTONS INTO TRANSMISSION CASE (a) Align the teeth of the No, 2 piston into the proper grooves, (b) Being careful not to damage the Ovings, press in the No. 2 with No. 1 first and reverse brake pistons into ‘the transmission case PLACE PISTON RETURN SPRING ONTO NO. 2 PISTON COMPRESS PISTON RETURN SPRING AND INSTALL SNAP RING IN GROOVE (a) Set SST a5 shown, and compress the return spring with SST. SST 09380-30020 (09350-07050) (0) Install the snap ring with snap cing pliers. Be sure the end gap of the snap ring isnot aligned with the spring retainer claw. 65 Technical Service Information VALVE BODY Upper Valve Booy Desert Spring 4 Nonceusale sort over Nave ea ana TURN OVER ASSEMBLY AND REMOVE TWENTY- FIVE BOLTS LIFT OFF UPPER VALVE BODY AND PLATE AS A. SINGLE UNIT Hold the valve body plate to the upper valve body. NOTE: Be careful that the check balls and strainer do ot fallout. ATSG Technical Service Information Lower Valve Body Rewiner Plug Relate Control Valve Staines No. 2Sotenois Retainer Accumulator Control Valve BR ine oN No.1 Solenoid Waar Retainer sieve 4 Nonrevsabe pact arm] DISASSEMBLY OF LOWER VALVE BODY REMOVE CHECK VALVE, PRESSURE RELIEF VALVE AND SPRINGS Check Valve @—~ Precrure Relist VaNe REMOVE THREE STRAINERS 67 Technical Service Information “anal CONFIAM CLIP AND FOUR RETAINERS ARE rain INSTALLED CORRECTLY REMOVE NO.1 AND NO.2 SOLENOIDS (a) Remove each bolt. (o} Remove the No. 1 and No. 2 solenoids from each bore. (c) Remove the O-rings. REMOVE NO.3 SOLENOID (a) Remove the bolt. (b) Remove the solenoid trom the bore. [c) Remove the O-ring REMOVE RELEASE CONTROL VALVE (a) Remove the retainer with a magnetic finger. (6) Remove the plug and release control valve. 68 Service Information Technical AW-4 CHECK BALL LOCATION Prior to 1991 the AW-4 modles used 9 check balls with three different sizes and had a combination of both stee! and rubber balls (igure 1). 1n 1991, they went to 8 checkballs all being rubber with two different sizes, The location of these balls are changed and they added an oll strainer (figure 2). A- RUBBER BALL —3.35mm (.250 in) B-STEELBALL —5.56mm (.2189 in) C-STEELBALL — 7.14mm (.2811 in) A~6.35mm (.250 in) B= 5.535mm (.218 in) Figure + Figure 2 AUTOMATIC TRANSMISSION SERVICE GROUP 69 Technical Service Information INSTALL NO.1 AND NO.2 SOLENOID [a) Install a new Orring to the solencia. (b} Instat the solenoid to the valve body. “Torque the bolt. Torque: 100 kg-em (7 felb, 10 Nem) MAKE SURE CLIP ANO FOUR RETAINERS ARE INSTALLED CORRECTLY - INSTALL THREE STRAINERS Install the three strainers to the valve body es shown, | je 19.5 10.768) 10.3 (0.4 INSTALL CHECK VALVE, PRESSURE RELIEF VALVE [Cr Meee sreure Reet Vale AND SPRINGS 70 4 ATSG Technical Service Information Upper Valve Body J ou] | Szaemtonnmenoge CRESS CCAESSION “© Deed on 1990 Models “ Daeteton 1869 Meets SUPRA Retain "Vlve Stopoee Pin eee Pr RETAINER & PIN (GRESSION SUPRA PICKUPS 8 RUNNERS) NOTE: Let designs chock bal size and mate See UPPER VALVE BODY CHECK BALL SPECIFICA ‘Locating Upper Valve Body Check Ball & Retainer (A308, AOF & A504) Service Information NOTE: Letor designates check bal alee and mor Seo UPPER VALVE BODY CHECK BALL SPECIFICA. TIONS tate, ny Tot Me USA, Fig, 4: Locating Upper Valve Body Check Bal & Retainer ane) UPPER VALVE BODY CHECK BALL SPECIFICATIONS No. of Cheek Bal at Bau Check Diamar Identteation Tye Bal etm) 008 TR or PUBEAF ow Youve 9500 (8.950) "8 (Grossi) Sa 6 rap s.s00) 8 (Supra GE) Se 7 reo seo) °° (Supra STE) ‘Stes 5 prep 6.360) Brow & shunned) Stee 8 res (s'so0) oe Sto 4 IT Bene) "0 (Grosida@ Supa uber TT 4 TI Bet a0) sse0 “e 4 ne 2500 (6.350), | "8 (Gress) 7 Bret 540) 8 (Supra GE) 2 oc Bier 540) 1B (Supra TM-GTE) Rubber Too a. B84 (840) ‘8 (Pehup& 4Runer) Rubber @ rane) wn Stel 1 an san) 1880 Futber 1 ns 2600 (6.250) ons (8466) wer 7 2 TI Booo easo) "Br (Crosse) ober 07 FT eet eso) (Supa mee) Fusber 2g TT rat sea) (Supra MGTE) Fubber U2 ret ese, 7B (Pekup &«Runnar) Rubber "8. tet esa) [Lows 15400) Fubber 94 “> ren isso) °C erunner AoH0eii Sea nn Baw faa) INSPECT VALVE SPRINGS. Check for damage, squarenes, rust and distorted coll, Measure the spring free height and replace if less than that shown below. eee Freeland (3) ome a na) (a) Tote 28 wa 13) 3-4 shift valve a 908 01.212) tw Sard son easier 282 (0990) (5) Locka rely wave 214 (0843) te) Seer ier 208 0.207) 1) Catach ae ne wa © 23a [me ware «o gason naar 28 (os B Technical Service Information AW 30-80LE VALVE BODY CHECKBALL LOCATIONS FOR 1988-1989 MODELS ONLY NO, REQUIRED 1 CHECKBALL DIAMETER @_RUBBER BALL 6.35 (.250") @_STEEL BALL 5,56 218") 7 ©_STEEL BALL 7,14 (.281") 1 Figure 1 AUTOMATIC TRANSMISSION SERVICE GROUP ” Technical Service Information AW 30-80LE VALVE BODY CHECKBALL LOCATIONS FOR 1990-1991 MODELS ONLY CHECKBALL DIAMETER NO. REQUIRED RUBBER BALL. 6.35 (.250") 1 RUBBER BALL 5.56 _(.218") 7 Figure 2 AUTOMATIC TRANSMISSION SERVICE GROUP 5 Technical Service Information Technical Service Information rovo7a 340H/e, ELECTRICAL PARTS INSPECT NEUTRAL START SWITCH Using an ohmmeter, check the continuity ofthe terminals for each switeh position shown in the table below. | It continuity between the terminals ie not a specified, replace the steh INSPECT SOLENOID Using an ohmmeter, check the resistance between terminal and body Standard resistance: 11 - 18.2, INSPECT SPEED SENSOR Connect an ohmmeter to the speed sensor and check that the meter deflects when the sensor is repeatedly brought lose to the rotor sensor magnet and removed from it 1 ATSG] Technical Service Information ASSEMBLY OF TRANSMISSION Disassembly, inspection and assembly of each com: onent group have been indicated in the preceding chapter. Before assembly, make sure, again, that all component groups are sssembled correctly. GENERAL ASSEMBLY NOTES: 1. The automatic transmission is eompoted of highly precisionsfiished parts, necessitating careful inspection before assembly because ven 2 small nick could cause fluid leakage or affect performance. 2. Before assembling new clutch discs and brake bands, soek them in automatic transmission fluid for atleast thirty minutes. 3. Apply automatic transmission fluid on the sliding or rotating surfaces of parts before assembly. 4. Use petroleum jelly to keep small parts in their places eis © =e 0 1 something wrong is found in a certain compo- rent group during. assembly, inspect and repair this group immediately. Recommended ATF: DEXRON® UL 5. Do not use adhesive cements on gaskets and similar parts. 6. When assembling the transmission, be sure to use new gaskets and O-rings. 7. Dry all parts with compressed air — never use shop rags, 8, Be sure to install the thrust bearings and races in the correct direction and position, ts © a) as © Technical Service Information INSTALL REAR PLANETARY GEAR, SECOND BRAKE DRUM AND OUTPUT SHAFT {a} Coat the assembled bearing and race with petroleum jelly and install it onto the ease NOTE: Assembled bearing and race diameter mm fin) Bearing ae ree Diameter Thee 302 (1543) Outise S77 (2272) (0) Align the teeth of the second brake drum, flanges,

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