3-1

TORQUE CONVERTER & TRANSMISSION

Page
GENERAL...............................................................3-2
0
HYDRAULIC CIRCUIT DIAGRAM .........................3-5
1
SPECIFICATIONS ..................................................3-6
2
COMPONENTS ......................................................3-7
TROUBLESHOOTING..........................................3-13
3
TRANSMISSION COVER & 4
CONTROL VALVE ASSY ...................................3-14 5
REMOVAL·INSTALLATION .....................................3-14
6
DISASSEMBLY·INSPECTION·REASSEMBLY ...........3-15
7
TORQUE CONVERTER·OIL PUMP .....................3-18
8
REMOVAL·INSTALLATION .....................................3-18
TORQUE CONVERTER & 9
TRANSMISSION ASSY ......................................3-21 10
REMOVAL·INSTALLATION .....................................3-21
11
TRANSMISSION ASSY........................................3-25
12
DISASSEMBLY·INSPECTION·REASSEMBLY ...........3-25
13
CLUTCH DRUM ASSY.........................................3-32
DISASSEMBLY·INSPECTION·REASSEMBLY ...........3-32
14
DIRECTION SWITCH ASSY ................................3-36 15
REMOVAL·INSTALLATION .....................................3-36 16
OIL PRESSURE MEASUREMENT AND 17
STALL TEST.......................................................3-37
18
19
20
21
E
3-2

GENERAL
Torque Converter

R F

F: Forward
R: Reverse
 3-3

Control Valve (Upper)

0
1
2
A A
3
B B
4
5
6
C C
7
8
9
10
11
12
A-A: Regulator valve
13
14
15
16
B-B: Inching valve
17
18
19
C-C: Accumulator
20
21
E
3-4

Control Valve (Lower)

A A

B B

C C

A-A: Safety valve

B-B: Shift change valve (R)

C-C: Shift change valve (F)

 Inching valve

Solenoid valve (R)

Shift change valve (R)

Accumulator

Solenoid
Safety valve valve (F)
HYDRAULIC CIRCUIT DIAGRAM

Regulator valve

Relief
valve

In-line strainer

Oil pump

R clutch Cooler
Shift change valve (F)

F clutch Oil
filter
3-5

9
8
7
6
5
4
3
2
1
0

E
11

21
20
19
18
17
16
15
14
13
12
10
3-6

SPECIFICATIONS
Item 1 speed torque converter
Maker Aisin
Torque converter type 3 elements, 1 stage, 2 phases type
Torque converter model AISIN
4Y·1DZ-II 2.68
Stall torque ratio
2Z 2.61
4Y·1DZ-II 2100
Stall speed rpm
2Z 2050
Control system Solenoid type selector valve
Clutch operating pressure (main pressure) 2 1108 (11.3) [161]
kPa (kgf/cm ) [psi]
Torque converter outlet pressure kPa (kgf/cm2) [psi] 392 (4.0) [57]
Torque converter oil capacity l (USgal) 8.0 (2.11)
Torque converter oil ATF GM Dexron® II

Note: The indicated oil pressure is at an engine speed of 2000 rpm.

Torque Converter Ratio

Torque Converter Ratio
Vehicle model Engine
Forward Reverse
1 ton series 4Y·1DZ-II 1.633 1.641
K2 ton series 4Y·1DZ-II ↑ ↑
4Y·1DZ-II ↑ ↑
2 ton series
2Z 1.323 1.341
K3 ton series 4Y·1DZ-II 1.633 1.641
1DZ-II ↑ ↑
3 ton series
4Y·2Z 1.323 1.341
4Y ↑ ↑
J3.5 ton series
2Z ↑ ↑
 3-7

COMPONENTS
Torque Converter Housing (4Y Engine Vehicle)

3201

Torque Converter Housing (1DZ-II·2Z Engine Vehicle)

3201
3-8

3201

Torque Converter

3202
 3-9

Torque Converter Clutch

3203

Torque Converter Gear

3204
3-10

Control Valve

3206

3206
 3-11

3206

Torque Converter Piping

3213
3-12

3213

Direction Switch

5701
 Disassembly and inspection
Components other than control valves On-board inspection
Control valve (torque converter & transmission)

Regulator valve
Inching valve
Shift change valve for F
Shift change valve for R
Safety valve
Accumulator for F, R
Solenoid valve for F
Solenoid valve for R
In-line strainer
Relief valve
Wire to solenoid
Oil strainer
Torque converter
Oil pump
Clutch drum for F
Clutch drum for R
Gear, bearing
Shift lever switch and
neutral start switch
ATF level and quality
Inching lever, and
wire cable
Oil pressure test
Stall test

Faulty starting No starting at F

No starting at R
TROUBLESHOOTING

No starting at any ranges

No starting at N

Large shock at At N F
starting (shifting)
At N R

after shifting
At N

start
Inching At starting
At R

Large time lag at At N F

starting (shifting)
At N R

At switch back F R

Slippage At F

At R

Others Starter fails to revolve at N.

Starter revolve at ranges other than N.

No inching operation

Overheating of transmission,
no air flow from breather

Abnormal noise
3-13
3-14

TRANSMISSION COVER & CONTROL VALVE ASSY

REMOVAL·INSTALLATION
T = N·m (kgf·cm) [ft·lbf]

T = 21.0 (214) [15.5]

Removal Procedure
1 Remove the lower panel.
2 Remove the toe board.
3 Disconnect the inching wire.
4 Disconnect the connector.
5 Remove the transmission cover & control valve ASSY.

Installation Procedure
The installation procedure is reverse of the removal procedure.
 3-15

DISASSEMBLY·INSPECTION·REASSEMBLY
T = N·m (kgf·cm) [ft·lbf]

T = 12.5 (127) [9.2]

3

T = 21.0 (214) [15.5] 5

4
T = 7.9 (81)
[5.8]
3

2
7

T = 20.2 (206) [14.9]

T = 7.9 (81) [5.8]

Disassembly Procedure
1 Disconnect the solenoid valve connector.
2 Remove the solenoid valve.
3 Remove the sleeve lock plate and solenoid wire ASSY.
4 Remove the inching lever.
5 Remove the inching level oil seal. [Point 1]
6 Remove the accumulator valve, inching valve and regulator valve. [Point 2]
7 Remove the lower valve body ASSY, oil strainer, relief valve piston and spring. [Point 3]
8 Remove the safety valve, F shift valve and R shift valve. [Point 4]

Reassembly Procedure
The reassembly procedure is reverse of the disassembly procedure.
3-16

Point Operations
[Point 1]
Reassembly:
SST(2)
SST 09950-76018-71................................. (1)
SST(1) (09950-60010)
09950-76020-71................................. (2)
(09950-70010)

[Point 2]
Service bolt Disassembly:
Remove the accumulator valve plug using the service bolt.
Service bolt size: M8×1.25

Inspection:
Measure free length of each valve spring.

Standard mm (in) Limit mm (in)

Inner 67.4 (3.390) 64.0 (3.220)
Accumulator valve
Outer 127.8 (5.031) 121.4 (4.780)
Plug side 64.2 (2.528) 61.0 (2.402)
Inching valve
Valve side 49.9 (1.965) 47.4 (1.866)
Regulator valve 132.4 (5.213) 125.8 (4.953)

[Point 3]
Reassembly:
Install the lower valve body.
1. Install the oil strainer, spring and relief valve piston on the
lower valve body, and put the gasket on top.
2. Reverse the above while maintaining the assembled state and
install it on the transmission cover.
 3-17

[Point 4]
Disassembly:
Press in the valve plug with its opening facing downwards and
remove the key.

Inspection:
Measure free length of each valve spring.
Standard mm (in) Limit mm (in)
F/R shift valve 59.8 (2.354) 56.8 (2.236)
Safety valve 59.8 (2.354) 56.8 (2.236)
3-18

TORQUE CONVERTER·OIL PUMP

REMOVAL·INSTALLATION
T = N·m (kgf·cm) [ft·lbf]

T = 21.0 (220) [15.9]

Removal Procedure
1 Drain torque converter oil.
2 Remove the engine ASSY. (See page 1-12.)
3 Remove the torque converter ASSY. [Point 1]
4 Remove the oil pump W/ stator shaft. [Point 2]
5 Remove the stator shaft. [Point 3]
6 Remove the oil pump drive gear and the oil pump driven gear. [Point 4]
7 Remove the oil seal. [Point 5]

Installation Procedure
The installation procedure is reverse of the removal procedure.

Point Operations
[Point 1]
Removal:
Be careful as the torque converter ASSY contains oil.
Oil
seals Installation:
Apply MP grease to the seal ring and oil seal lip before
installation.
Installation:
Install while rotating the torque converter ASSY so that the
extension claw engages with the groove in the oil pump drive gear.
 3-19

[Point 2]
Service tap
Removal:
SST 09950-76014-71
(09950-40011)

Service tap

SST

Installation:
Be careful not to install the pre-coated bolts in incorrect
positions.
Installation:
When reusing precoated bolts, apply thread tightener (08833-
76002-71 (08833-00080)) to the threaded part.

[Point 3]
Removal:
Put match marks on the oil pump and stator shaft ASSY.
Installation:
Align match marks when installing.

[Point 4]
Inspection:
Measure the clearance between the oil pump driven gear and
pump body.
Limit: 0.3 mm (0.012 in)

Inspection:
Measure the clearance between the pump body and each
gear.
Standard: 0.042 ~ 0.080 mm (0.002 ~ 0.003 in)
3-20

Inspection:
The marks have no meaning for reassembly.

Marks

[Point 5]
Installation:
SST 09370-10410-71
SST
 3-21

TORQUE CONVERTER & TRANSMISSION ASSY

REMOVAL·INSTALLATION
T = N·m (kgf·cm) [ft·lbf]

29 27

24 9

Engine mounting nut T = 53.2 ~ 98.0 (550 ~ 1000) [39.8 ~ 72.3]

Front insulator set bolt
Torque converter housing set bolt
Drive plate set bolt (for connecting to engine crankshaft)
Drive plate set bolt (for connecting to torque converter)
T = 68.0 ~ 102.0 (700 ~ 1050) [50.6 ~ 76.0]
T = 29.4 ~ 44.1 (300 ~ 450) [21.7 ~ 32.6]
4Y engine vehicle
T = 56.8 ~ 64.7 (580 ~ 660) [42.0 ~ 47.8]
1DZ-II·2Z engine vehicle
T = 76.4 ~ 93.1 (780 ~ 950) [56.4 ~ 68.7]
T = 14.7 ~ 21.6 (150 ~ 220) [10.9 ~ 15.9]
3-22

Removal Procedure
1 Remove the engine hood. (Refer to page 11-10)
2 Remove the lower panel.
3 Remove the toe board.
4 Drain coolant.
5 Remove the battery.
6 Remove the sedimenter bracket set bolt and leave it free. (1DZ-II·2Z engine vehicle)
7 Disconnect the accelerator wire. (1DZ-II·2Z engine vehicle)
8 Disconnect the fuel hose.
9 Remove the relay block and leave it free.
10 Remove the battery set plate.
11 Remove the air cleaner and air inlet.
12 Remove the exhaust pipe cover plate.
13 Disconnect the exhaust pipe.
14 Remove the RH side step and side cover.
15 Disconnect the main harness connector inside the RH side cover.
16 Disconnect the oil pump-to-oil control valve hose.
17 Disconnect the inching wire.
18 Disconnect the torque converter cooler hose (on the transmission side) and drain oil from the torque converter.
[Point 1]
19 Disconnect the torque converter cooler hose (on the radiator side). [Point 2]
20 Disconnect the water hose.
21 Remove the radiator and fan shroud.
22 Remove the under cover.
23 Disconnect the wiring and wire harness clamps around the engine and transmission.
24 Remove the oil pump set bolt, and leave it free.
25 Remove the propeller shaft under cover and propeller shaft. (Refer to page 5-3)
26 Remove the engine mount nut.
27 Attach the SST to the engine W/ torque converter and transmission ASSY. [Point 3]
28 Remove the front insulator set bolt.
29 Remove the engine W/ torque converter & transmission ASSY. [Point 4]
30 Remove the cover plate.
31 Remove the drive plate set bolts (6 bolts). [Point 5]
32 Disconnect the engine ASSY from the torque converter housing.

Installation Procedure
The installation procedure is the reverse of the removal procedure.
Note:
After installing the engine ASSY, perform air bleeding of the fuel system. (1DZ-II·2Z engine vehicle) (refer to
page 1-18)
 3-23

Point Operations
[Point 1]
Removal:
Put match marks on the transmission case and torque
converter cooler hose.

[Point 2]
Removal:
Put match marks on the radiator and torque converter cooler
hose.

SST(1) [Point 3]
SST(2) Removal•Installation:
SST 09010-20111-71 ................................. (1)
09010-23320-71................................. (2)

[Point 4]
Removal•Installation:
SST Move the SST hook position to adjust the balance.
3-24

[Point 5]
Removal•Installation:
Turn the flywheel using the crankshaft pulley set bolt.

Crankshaft
pulley set bolt
 3-25

TRANSMISSION ASSY
DISASSEMBLY·INSPECTION·REASSEMBLY
T = N·m (kgf·cm) [ft·lbf]

T = 56.0 (571) 16
[41.3]
17
T = 12.7 (129.5)
[9.4]
14 10

14
14
9
8

11
7

T = 69.0 ~ 96.0
T = 19.0 (193.7) [14.0] (703.6 ~ 978.9) 13
[50.9 ~ 70.8] 15
14
12
4

14 6
T = 21.0 (214.1) [15.5]

3
T = 49.0 (499.7)
[36.2]

T = 32 ~ 48 T = 56.0
(326.3 ~ 489.5) (571.0)
[23.6 ~ 35.4] [41.3]
3-26

Disassembly Procedure
1 Drain torque converter oil.
2 Remove the transmission cover & control valve ASSY.
3 Remove the torque converter.
4 Remove the oil pump W/ stator shaft ASSY and shim. [Point 1]
5 Remove the rear case. [Point 2]
6 Remove the output gear cover, output gear and shim. [Point 3]
7 Remove the counter gear and shim. [Point 4]
8 Remove the counter gear shaft and main shaft ASSY. [Point 5]
9 Remove the spacer, main shaft rear bearing, reverse clutch gear, forward clutch gear, and reverse & forward
clutch drum ASSY. [Point 6]
(Refer to page 3-51 for disassembly, inspection and reassembly of the clutch drum ASSY)
10 Remove the forward clutch gear bearing. [Point 7]
11 Remove the reverse clutch gear bearing. [Point 8]
12 Remove the output shaft. [Point 9]
13 Remove the output shaft dust deflector. [Point 10]
14 Remove the main shaft front bearing, the counter gear bearing and output gear bearing. [Point 11]
15 Remove the output shaft oil seal. [Point 12]
16 Remove the oil strainer. [Point 13]
17 Remove the oil filter. [Point 14]

Reassembly Procedure
The reassembly procedure is the reverse of the disassembly procedure.

Point Operations
Service tap
[Point 1]
Disassembly:
SST 09950-76014-71
(09950-40011)
Service tap

SST

Reassembly:
Be careful not to install the pre-coated bolts in incorrect
positions.
Reassembly:
When reusing precoated bolts, apply thread tightener (08833-
76002-71 (08833-00080)) to the threaded part.
 3-27

Reassembly:
Adjust the thrust clearance of the main shaft system.
1. Temporarily assemble the oil pump W/ stator shaft ASSY,
shim, and rear case, and measure the thrust clearance of the
main shaft gear system.
A
Standard: A = 0.10 ~ 0.24 mm (0.004 ~ 0.009 in)

2. If the standard is not satisfied, increase or decrease the shim

Shim thickness for adjustment.
Mark Thickness mm (in)
A 1.08 ~ 1.12 (0.043 ~ 0.044)
B 1.18 ~ 1.22 (0.046 ~ 0.048)
C 1.28 ~ 1.32 (0.050 ~ 0.052)
E 1.38 ~ 1.42 (0.054 ~ 0.056)
F 1.48 ~ 1.52 (0.058 ~ 0.060)
G 1.58 ~ 1.62 (0.062 ~ 0.064)
H 1.68 ~ 1.72 (0.066 ~ 0.068)
J 1.78 ~ 1.82 (0.070 ~ 0.072)
K 1.88 ~ 1.92 (0.074 ~ 0.076)
L 1.98 ~ 2.02 (0.078 ~ 0.080)
M 2.08 ~ 2.12 (0.082 ~ 0.083)
N 2.18 ~ 2.22 (0.086 ~ 0.087)
P 2.28 ~ 2.32 (0.090 ~ 0.091)
R 2.38 ~ 2.42 (0.094 ~ 0.095)
S 2.48 ~ 2.52 (0.098 ~ 0.099)

[Point 2]
Disassembly:
Insert a flat head screwdriver in the cut portion of the rear case
and remove the case.

Magnet Reassembly:
Assemble after removing iron powder staying on the magnet.
3-28

[Point 3]
Reassembly:
Adjust the output gear thrust clearance.
1. Temporarily install the output gear, shim and rear case, and
measure the output gear thrust clearance.
Standard: A = 0.10 ~ 0.49 mm (0.004 ~ 0.019 in)
A

Shim 2. If the standard is not satisfied, increase or decrease the shim

thickness for adjustment.
Mark Thickness mm (in)
0 0.375 ~ 0.425 (0.015 ~ 0.017)
2 0.67 ~ 0.75 (0.026 ~ 0.030)
4 0.855 ~ 0.945 (0.034 ~ 0.037)
6 1.065 ~ 1.175 (0.042 ~ 0.046)
7 1.12 ~ 1.24 (0.044 ~ 0.049)

[Point 4]
Reassembly:
Adjust the counter gear thrust clearance.
1. Temoporarily assemble the counter gear, shim and rear case,
and measure the thrust clearance of the counter gear.
Standard: 0.10 ~ 0.54 mm (0.004 ~ 0.021 in)

Shim
2. If the standard is not satisfied, increase or decrease the shim
thickness for adjustment.
Mark Thickness mm (in)
0 0.375 ~ 0.425 (0.015 ~ 0.017)
2 0.67 ~ 0.75 (0.026 ~ 0.030)
3 0.855 ~ 0.945 (0.034 ~ 0.037)
4 1.01 ~ 1.11 (0.040 ~ 0.044)
5 1.12 ~ 1.24 (0.044 ~ 0.049)
6 1.24 ~ 1.36 (0.049 ~ 0.054)

[Point 5]
Disassembly•Reassembly:
Disassemble or reassemble the counter gear shaft together
with the main shaft ASSY.
 3-29

[Point 6]
Inspection:
Measure the seal ring side clearance.
Limit: 0.2 mm (0.008 in)

Reassembly:
After aligning the clutch disc serration using a screwdriver or
the like, reassemble the clutch gear.

[Point 7]
Disassembly:
SST 09950-76018-71................................. (1)
(09950-60010)
SST(2) 09950-76020-71................................. (2)
(09950-70010)

SST(1)

Reassembly:
SST 09950-76019-71................................. (1)
(09950-60020)
09950-76020-71................................. (2)
(09950-70010)
SST(2)
SST(1)

[Point 8]
Disassembly:
SST 09950-76018-71................................. (1)
(09950-60010)
SST(2)
09950-76020-71................................. (2)
(09950-70010)
SST(1)
3-30

Reassembly:
SST 09950-76019-71................................. (1)
(09950-60020)
09950-76020-71................................. (2)
SST(2) (09950-70010)

SST(1)

[Point 9]
Disassembly•Reassembly:
SST 09905-76002-71
(09905-00012)

SST

[Point 10]
Reassembly:
SST 09370-20270-71

SST

[Point 11]
Disassembly:

SST
SST 09320-23000-71

Reassembly:
SST(2) SST 09950-76018-71................................. (1)
(09950-60010)
09950-76020-71................................. (2)
(09950-70010)

SST(1)
 3-31

[Point 12]
Disassembly•Reassembly:
Use a flat head screwdriver or the like to disassemble or
reassemble the output shaft oil seal.
Reassembly:
A Reassemble the output shaft oil seal to the position A in the
illustration.
A = 6.7 ~ 7.7 mm (0.264 ~ 0.303 in)

[Point 13]
Disassembly:
Pinch the rib part of the oil strainer with long-nosed pliers, and
remove the oil strainer.

[Point 14]
Disassembly•Reassembly:
SST 09228-76004-71
(09228-07501)

SST

Clutch operation check after reassembly

F
R Blow air through the oil hole on top of the transmission case and
check that each clutch piston operates normally.

F R
3-32

CLUTCH DRUM ASSY

DISASSEMBLY·INSPECTION·REASSEMBLY

Disassembly Procedure
1 Remove the snap ring.
2 Remove the backing plate, clutch discs, clutch plates and camber plate. [Point 1]
3 Remove the snap ring and clutch piston return spring. [Point 2]
4 Remove the clutch piston, piston ring and seal ring. [Point 3]

Reassembly Procedure
The reassembly procedure is reverse of the disassembly procedure.

Point Operations
[Point 1]
Inspection:
Measure thickness of the clutch disc.
Standard: 2.6 mm (0.102 in)
Limit: 2.3 mm (0.091 in)
 3-33

Inspection:
Measure thickness of the clutch plate.
Standard: 2.0 mm (0.079 in)
Limit: 1.8 mm (0.071 in)

Inspection:
Measure height of the camber plate curving.
Standard: 3.4 mm (0.134 in)
Limit: 3.1 mm (0.122 in)

Reassembly:
Clutch gear side
Reassemble with the punched side facing upwards (the clutch
gear side).

Piston side
Punching
3-34

Reassembly:
Install the clutch plates and clutch discs alternately on the
clutch drum while applying torque converter oil.
Number of clutch discs
1 ton series 4Y·1DZ-II models 4
K2·K3 ton series 4Y·1DZ-II models 5
4Y·1DZ-II models 5
Camber plate 2·3 ton series
2Z model 5
4Y model 5
J3.5 ton series
2Z model 5

Reassembly:
Adjust the clearance between the backing plate and clutch
disc.
1. Install the camber plate, clutch plates, clutch discs, backing
plate and snap ring on the clutch drum.
2. Measure clearance between the backing plate and snap ring
using thickness gauges.

Standard:
4-disc specification: 0.8 ~ 1.4 mm (0.031 ~ 0.055 in)
5-disc specification: 1.0 ~ 1.6 mm (0.039 ~ 0.063 in)

3. If the measured value is out of the specified range, select a

Identifying grooves suitable backing plate.
Backing plate thickness
A Identifying grooves

A 5.7 mm (0.224 in) 0

6.2 mm (0.244 in) One groove
6.7 mm (0.264 in) Two grooves

Identifying grooves Reassembly:

Install the backing plate with its stepped side (with groove)
facing upward (on the clutch gear side).
 3-35

[Point 2]
Disassembly•Reassembly:
SST(1) Compress the return spring using the SST and remove or
install the snap ring.
SST(2) Tie two hooks of the SST using a wire or string as shown in the
illustration to fix it in the clutch drum.
SST 09220-22001-71................................. (1)
09905-76002-71................................. (2)
(09905-00012)
Wire

Caution:
The hooks may come off the clutch drum and spring may jump
out when using the SST. Be careful not to allow the hooks to
come off the drum when removing or installing the snap ring.
Inspection:
Measure free length of the clutch piston return spring.
Standard: 63.4 mm (2.496 in)
Limit: 58.5 mm (2.303 in)

[Point 3]
Disassembly:
Pinch the rib of clutch piston using pliers with cloth in-between
and remove the piston.
Reassembly:
Apply torque converter oil on the piston ring and seal ring, and
assemble the clutch piston.
3-36

DIRECTION SWITCH ASSY

REMOVAL·INSTALLATION

1
3

Disassembly Procedure
1 Remove the steering column cover.
2 Disconnect the connector.
3 Remove the direction switch ASSY. [Point 1]

Installation Procedure
The installation procedure is reverse of the removal procedure.

Point Operations
23 22 21 20 19 18 17 16 15
[Point 1]
32 31 30 29 28 27 26 25 24
Inspection:
LH spec. RH spec. Inspect for continuity between the pins of the switch connector.
15: — 15: VR
16: IG2 16: Ra (P:Position, T:Terminal No., :Continuous)
17: N 17: ST
18: IG1 18: VF2 P T N IG1 IG2 VF ST VR Ra
19: VF 19: VF
F1
20: VF2 20: IG1
21: ST 21: N
22: Ra 22: IG2 N
23: VR 23: —
VF : Forward solenoid
VF2 : Forward (F2) solenoid R
VR : Reverse solenoid Rr
ST : Starting motor relay Ra
Ra : Backup lamp & buzzer
 3-37

OIL PRESSURE MEASUREMENT AND

STALL TEST
Front 1. Maintain the vehicle horizontally and warm up the engine with
the direction switch at the N position.
2. Measure the oil level.
(1) Stop the engine, and after 30 seconds has passed,
inspect the oil level using the level guage.
Back
(2) If the oil level is not between F (upper limit) and L (lower
limit), adjust it to an appropriate level.

Clutch pressure (F) Clutch pressure (R) 3. Measure the oil pressure.
Main
pressure (1) Check and adjust the engine speed.
(2) Stop the engine and jack up at the front axle to raise
wheels (both tires).
(3) Set the oil pressure gauge. (If three oil pressure gauges
are available, measure the main, clutch and torque
converter outlet pressures at a time.)
Use the adapter (SST) for the main pressure and clutch
pressure detection port.
Outlet pressure
SST 09350-23320-71
(SST thread size: Valve side 5/16 UNF, Oil pressure
gauge side PT1/8)
(4) Start the engine, set the direction switch to the N position.
Measure the main pressures at idle and 2000 rpm, and
the torque converter outlet pressure at 2000 rpm.
(5) Operate the direction switch to the F and R positions, and
measure the respective clutch working pressures at idle
and at 2000 rpm.
Note:
Do not step on the inching pedal while measuring oil pressure.
Standard:
kPa (kgf/cm2) [psi]

Detecting pressure Plug size Idle 2000 rpm

735 ~ 1324 (7.5 ~ 13.5)
Main pressure PT1/8 (SST) 890 ~ 1270 (9.1 ~ 13.0) [129 ~ 185]
[106.6 ~ 192.0]
Clutch pressure ↑ ↑ 890 ~ 1270 (9.1 ~ 13.0) [129 ~ 185]
Torque converter outlet
PT1/8 — 80 ~ 540 (0.8 ~ 5.5) [11.3 ~ 78.2]
pressure
3-38

4. Carry out the stall test.

(1) Load cargo having near the permissible maximum load,
firmly set stoppers at the front and rear wheels, and
activate the parking brake.
Caution:
Prevent the vehicle from moving by pulling at the rear by a
wire as shown, to perform the stall test safely.

(2) Warm up the engine and measure the idle speed, no-load
static maximum revolution and relief down.
(3) Set the direction switch to the forward position, depress
Accelerator pedal the accelerator pedal all the way and measure the stall
speed after the engine speed is stabilized.
Standard:
4Y: Approx. 2050 rpm
1DZ-II: Approx. 2100 rpm
2Z: Approx. 2050 rpm