Almera Tino V10 (2003 year). Manual — part 29
REPAIR FOR COMPONENT PARTS
AT-449
[ALL]
D
E
F
G
H
I
J
K
L
M
A
B
AT
d.
Install pilot filter.
e.
Place lower body as shown in illustration (side of inter body face
up). Install steel balls in their proper positions.
f.
Install inter body on upper body using reamer bolts “F”
as
guides.
●
Be careful not to dislocate or drop steel balls.
g.
Install check balls, fluid cooler relief valve springs and T/C pres-
sure holding spring in their proper positions in lower body.
h.
Install lower separating gasket, lower inter separating gasket
and lower separating plate in order shown in illustration.
SAT074F
SAT870J
SAT076F
MCIB9019E
BAT002
AT-450
[ALL]
REPAIR FOR COMPONENT PARTS
i.
Install bolts “E” from bottom of lower body. Using bolts “E” as
guides, install separating plate and gaskets as a set.
j.
Temporarily install support plates on lower body.
k.
Install lower body on inter body using reamer bolts “F”
as
guides and tighten reamer bolts “F” slightly.
2.
Install O-rings to solenoid valves and terminal body.
●
Apply ATF to O-rings.
3.
Install and tighten bolts.
Bolt length, number and location:
F: Reamer bolt and nut
SAT078F
AAT536
SAT317G
Bolt symbol
A
B
C
D
E
F
G
Bolt length “
”
13.5 mm
(0.531 in)
58.0 mm
(2.283 in)
40.0 mm
(1.575 in)
66.0 mm
(2.598 in)
33.0 mm
(1.299 in)
78.0 mm
(3.071 in)
18.0 mm
(0.709 in)
Number of bolts
6
3
6
11
2
2
1
REPAIR FOR COMPONENT PARTS
AT-451
[ALL]
D
E
F
G
H
I
J
K
L
M
A
B
AT
a.
Install and tighten bolts B to specified torque.
b.
Install solenoid valve assembly and line pressure solenoid valve
to lower body.
c.
Remove reamer bolts F and set oil strainer on control valve
assembly.
d.
Reinstall reamer bolt F from lower body side.
SAT869J
: 7 - 9 N-m (0.7 - 0.9 kg-m, 61 - 78 in-lb)
SAT081F
SAT316GA
SAT323G
AT-452
[ALL]
REPAIR FOR COMPONENT PARTS
e.
Set oil strainer, then tighten bolts A , C , D and nuts F to speci-
fied torque.
f.
Tighten bolts e to specified torque.
: 7 - 9 N-m (0.7 - 0.9 kg-m, 61 - 78 in-lb)
SAT083F
: 3.4 - 4.4 N-m (0.35 - 0.45 kg-m, 30 - 39 in-lb)
SAT084FA
REPAIR FOR COMPONENT PARTS
AT-453
[ALL]
D
E
F
G
H
I
J
K
L
M
A
B
AT
Control Valve Upper Body
ECS009CK
COMPONENTS
Numbers preceding valve springs correspond with those shown in
AT-519, "SERVICE DATA AND SPECIFI-
.
1.
Control valve upper body
2.
Return spring
3.
Overrun clutch reducing valve
4.
Plug
5.
Retainer plate
6.
Torque converter relief valve
7.
Return spring
8.
Retainer plate
9.
Torque converter clutch control valve
10. Return spring
11.
Plug
12. Sleeve
13. Retainer plate
14. 1-2 accumulator valve
15. Return spring
16. Plug
17. Retainer plate
18. Cooler check valve
19. Return spring
20. Plug
21. Retainer plate
22. Retainer plate
23. Return spring
24. Pilot valve
25. Retainer plate
26. Plug
27. 1-2 accumulator piston
28. Return spring
29. 1-2 accumulator retainer plate
30. Retainer plate
31. Plug
32. 1st reducing valve
33. Return spring
34. Retainer plate
35. Return spring
36. 3-2 timing valve
SAT863J
AT-454
[ALL]
REPAIR FOR COMPONENT PARTS
DISASSEMBLY
1.
Remove valves at retainer plates.
●
Do not use a magnetic pick-up tool.
a.
Use a screwdriver to remove retainer plates.
b.
Remove retainer plates while holding spring, plugs or sleeves.
●
Remove plugs slowly to prevent internal parts from jump-
ing out.
c.
Place mating surface of valve body face down, and remove
internal parts.
●
If a valve is hard to remove, place valve body face down
and lightly tap it with a soft hammer.
●
Be careful not to drop or damage valves and sleeves.
SAT321G
SAT135D
SAT138D
SAT137D
REPAIR FOR COMPONENT PARTS
AT-455
[ALL]
D
E
F
G
H
I
J
K
L
M
A
B
AT
INSPECTION
Valve Spring
●
Measure free length and outer diameter of each valve spring.
Also check for damage or deformation.
●
Replace valve springs if deformed or fatigued.
Control Valves
●
Check sliding surfaces of valves, sleeves and plugs.
ASSEMBLY
●
Lay control valve body down when installing valves. Do not
stand the control valve body upright.
1.
Lubricate the control valve body and all valves with ATF. Install
control valves by sliding them carefully into their bores.
●
Be careful not to scratch or damage valve body.
●
Wrap a small screwdriver with vinyl tape and use it to insert
the valves into their proper positions.
Inspection standard
:Refer to
DATA AND SPECIFICATIONS
(SDS)"
.
SAT138D
SAT139D
SAT140DA
SAT141D
AT-456
[ALL]
REPAIR FOR COMPONENT PARTS
1-2 Accumulator Valve
●
Install 1-2 accumulator valve. Align 1-2 accumulator retainer
plate from opposite side of control valve body.
●
Install return spring, 1-2 accumulator piston and plug.
1.
Install retainer plates.
●
Install retainer plate while pushing plug or return spring.
Retainer Plate (Upper Body)
Unit: mm (in)
●
Install proper retainer plates.
Refer to
AT-453, "Control Valve Upper Body"
.
SAT142D
SAT143D
No.
Name of control valve
Width A
Length B
22
Pilot valve
6.0 (0.236)
21.5 (0.846)
30
1st reducing valve
34
3-2 timing valve
8
Torque converter relief valve
17
1-2 accumulator valve
38.5 (1.516)
25
1-2 accumulator piston
5
Overrun clutch reducing valve
24.0 (0.945)
21
Cooler check valve
13
Torque converter clutch control valve
28.0 (1.102)
SAT086F
REPAIR FOR COMPONENT PARTS
AT-457
[ALL]
D
E
F
G
H
I
J
K
L
M
A
B
AT
Control Valve Lower Body
ECS009CL
COMPONENTS
Numbers preceding valve springs correspond with those shown in
AT-519, "SERVICE DATA AND SPECIFI-
.
1.
Control valve lower body
2.
Return spring
3.
Shift valve B
4.
Plug
5.
Retainer plate
6.
Pressure modifier valve
7.
Return spring
8.
Parallel pin
9.
Sleeve
10. Piston
11.
Return spring
12. Retainer plate
13. Manual valve
14. Retainer plate
15. Sleeve
16. Plug
17. Spring seat
18. Return spring
19. Pressure regulator valve
20. Retainer plate
21. Plug
22. Overrun clutch control valve
23. Return spring
24. Retainer plate
25. Plug
26. Accumulator control valve
27. Return spring
28. Retainer plate
29. Return spring
30. Shift valve A
31. Retainer plate
32. Plug
33. Plug
34. Return spring
35. Shuttle control valve
SAT864J
AT-458
[ALL]
REPAIR FOR COMPONENT PARTS
DISASSEMBLY
●
Remove valves at retainer plate.
For removal procedures, refer to
.
INSPECTION
Valve Springs
●
Check each valve spring for damage or deformation. Also mea-
sure free length and outer diameter.
●
Replace valve springs if deformed or fatigued.
Control Valves
●
Check sliding surfaces of control valves, sleeves and plugs for damage.
ASSEMBLY
●
Install control valves.
For installation procedures, refer to
.
Retainer Plate (for control valve lower body)
Unit: mm (in)
●
Install proper retainer plates.
Refer to
AT-457, "Control Valve Lower Body"
.
SAT872J
Inspection standard
:Refer to
.
SAT138D
SAT872J
Name of control valve
No.
Length A
Length B
Type
Pressure regulator valve
14
6.0
(0.236)
28.0
(1.102)
I
Accumulator control valve
24
Shift valve A
28
Overrun clutch control valve
20
Pressure modifier valve
12
Shuttle control valve
31
Shift valve B
5
—
—
II
SAT089F
REPAIR FOR COMPONENT PARTS
AT-459
[ALL]
D
E
F
G
H
I
J
K
L
M
A
B
AT
Reverse Clutch
ECS009CM
COMPONENTS
DISASSEMBLY
1.
Check operation of reverse clutch
a.
Install seal ring onto drum support of oil pump cover and install
reverse clutch assembly. Apply compressed air to oil hole.
b.
Check to see that retaining plate moves to snap ring.
c.
If retaining plate does not contact snap ring:
●
D-ring might be damaged.
●
Oil seal might be damaged.
●
Fluid might be leaking past piston check ball.
2.
Remove snap ring.
3.
Remove drive plates, driven plates, retaining plate, and dish
plates.
4.
Set Tool on spring retainer and remove snap ring from reverse
clutch drum while compressing return springs.
●
Set Tool directly over springs.
●
Do not expand snap ring excessively.
5.
Remove spring retainer and return springs.
SAT485JA
SAT155D
SAT156D
AAT489
AT-460
[ALL]
REPAIR FOR COMPONENT PARTS
●
Do not remove return spring from spring retainer.
6.
Remove piston from reverse clutch drum by turning it.
7.
Remove D-ring and oil seal from piston.
INSPECTION
Reverse Clutch Snap Ring, Spring Retainer and Return Springs
●
Check for deformation, fatigue or damage.
●
If necessary, replace.
●
When replacing spring retainer and return springs, replace them as a set.
Reverse Clutch Drive Plates
●
Check facing for burns, cracks or damage.
●
Measure thickness of facing.
●
If not within wear limit, replace.
SAT301E
SAT159D
SAT138E
Thickness of drive plate:
Standard value: 2.0 mm (0.079 in)
Wear limit: 1.8 mm (0.071 in)
SAT162D
REPAIR FOR COMPONENT PARTS
AT-461
[ALL]
D
E
F
G
H
I
J
K
L
M
A
B
AT
Reverse Clutch Dish Plates
●
Check for deformation or damage.
●
Measure thickness of dish plate.
●
If deformed or fatigued, replace.
Reverse Clutch Piston
●
Make sure that check balls are not fixed.
●
Apply compressed air to check ball oil hole opposite the return
spring. Make sure there is no air leakage.
●
Apply compressed air to oil hole on return spring side to make
sure that air leaks past ball.
ASSEMBLY
1.
Install D-ring and oil seal on piston.
●
Take care with the direction of oil seal.
●
Apply ATF to both parts.
2.
Install piston assembly by turning it slowly.
●
Apply ATF to inner surface of drum.
Thickness of dish plate “T”: 2.8 mm (0.110 in)
SAT163D
SAT164D
SAT160DA
SAT159D
AT-462
[ALL]
REPAIR FOR COMPONENT PARTS
3.
Install return springs and spring retainer on piston.
4.
Set Tool on spring retainer and install snap ring while compress-
ing return springs.
●
Set Tool directly over return springs.
5.
Install drive plates, driven plates, retaining plate and dish plates.
●
Do not align the projections of any two dish plates.
●
Take care with order and direction of plates.
6.
Install snap ring.
7.
Measure clearance between retaining plate and snap ring. If not
within allowable limit, select proper retaining plate.
8.
Check operation of reverse clutch.
Refer to
.
SAT168D
AAT489
SAT156D
Specified clearance:
Standard: 0.5 - 0.8mm (0.020 - 0.031 in)
Allowable limit: 1.2 mm (0.047 in)
Retaining plate:
Refer to
AT-519, "SERVICE DATA AND SPECIFICA-
.
SAT174D
SAT173D
REPAIR FOR COMPONENT PARTS
AT-463
[ALL]
D
E
F
G
H
I
J
K
L
M
A
B
AT
High Clutch
ECS009CN
COMPONENTS
DISASSEMBLY
1.
Check operation of high clutch.
a.
Apply compressed air to oil hole of input shaft with nylon cloth.
●
Stop up hole on opposite side of input shaft with nylon
cloth.
b.
Check to see that retaining plate moves to snap ring.
c.
If retaining plate does not contact snap ring:
●
D-ring might be damaged.
●
Oil seal might be damaged.
●
Fluid might be leaking past piston check ball.
2.
Remove seal rings from input shaft.
●
Always replace when removed.
SAT874J
SAT176D
SAT177D
AT-464
[ALL]
REPAIR FOR COMPONENT PARTS
3.
Remove snap ring.
4.
Remove drive plates, driven plates and retaining plate.
5.
Set Tool on spring retainer and remove snap ring from high
clutch drum while compressing return springs.
●
Set Tool directly over springs.
●
Do not expand snap ring excessively.
6.
Remove spring retainer and return springs.
●
Do not remove return spring from spring retainer.
7.
Remove piston from high clutch drum by turning it.
8.
Remove D-ring and oil seal from piston.
SAT178D
AAT683
SAT302E
SAT189D
SAT139E
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