Toyota Automatic Transmission A340 Series. Repair Manual — part 10

AT8164

AT6427

♦ Non−reusable part

Cushion Plate

Plate

Flange

S SUPRA

S CRESSIDA

Snap Ring

7M−GTE

Cushion Plate

Plate

S TRUCK

S 4 RUNNER

Flange

Oil Seal Ring

3VZ−E

♦ O−Ring

♦ O−Ring

Disc

Snap Ring

Race

Bearing

Bearing

Forward Clutch Drum

Snap Ring

Forward Clutch Piston

Piston Return Spring

Disc

Forward Clutch

COMPONENTS

DISASSEMBLY OF FORWARD CLUTCH

1.

REMOVE FORWARD CLUTCH ASSEMBLY FROM

DIRECT CLUTCH ASSEMBLY

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AUTOMATIC TRANSMISSION

Component Parts (Forward Clutch)

AT−69

AT8176

AT8177

AT8436

SST

AT8165

AT7843

SST

2.

PLACE FORWARD CLUTCH ONTO OVERDRIVE

SUPPORT
(a)

Place wooden blocks, etc. to prevent forward

clutch shaft from touching the work stand, and

place the O/D support on them.

(b)

Place the forward clutch onto the O/D support.

3.

CHECK PACK CLEARANCE OF FORWARD CLUTCH
Using SST and a dial indicator, measure the forward

clutch piston stroke applying and releasing the com-

pressed air (4−8 kg/cm

2

, 57 − 114 psi or 392 − 785

kPa) as shown.

SST

09350−30020 (09350−06120)

Pack clearance:

(22R−E)

0.4 − 0.8 mm (0.016 − 0.031 in.)

(7M−GTE)

0.6 − 1.0 mm (0.024 − 0.039 in.)

(Others)

0.5 − 0.9 mm (0.020 − 0.035 in.)

If the values are nonstandard, inspect the discs.

4.

REMOVE FLANGE, PLATES AND DISCS
(a)

Remove the snap ring from the forward clutch drum.

(b)

Remove the flange, plates and discs.

(22R−E)
One flange, four plates and four discs
(7M−GTE)
One flange, six plates and six discs
(Others)
One flange, five plates and five discs

5.

REMOVE CUSHION PLATE

6.

REMOVE PISTON RETURN SPRING
(a)

Place SST on the spring retainer and compress

the return spring with a shop press.

SST

09350−30020 (09350−07040)

(b)

Using snap ring pliers, remove the snap ring.

(c)

Remove the piston return spring.

AT−70

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AUTOMATIC TRANSMISSION

Component Parts (Forward Clutch)

AT8179

AT8180

AT5820

Printed

Numbers

AT8170

AT8178

7.

REMOVE FORWARD CLUTCH PISTON
(a)

Place the forward clutch drum onto the O/D support.

(b)

Hold the forward clutch piston with hand, apply com-

pressed air to the O/D support to remove the forward

clutch piston.

(c)

Remove the forward clutch piston.

(d)

Remove the two O−rings from the piston.

8.

REMOVE O−RING FROM FORWARD CLUTCH DRUM

9.

REMOVE OIL SEAL RINGS

INSPECTION OF FORWARD CLUTCH

1.

INSPECT DISC, PLATE AND FLANGE
Check to see if the sliding surface of the disc, plate and

flange are worn or burnt. If necessary, replace them.

HINT:

S

If the lining of the disc is peeling off or discolored,

or even if parts of the printed numbers are de-

faced, replace all discs.

S

Before assembling new discs, soak them in ATF

for at least fifteen minutes.

2.

CHECK FORWARD CLUTCH PISTON
(a)

Check that the check ball is free by shaking the

piston.

(b)

Check that the valve does not leak by applying

low−pressure compressed air.

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AUTOMATIC TRANSMISSION

Component Parts (Forward Clutch)

AT−71

AT8179

AT8442

AT8173

AT8171

AT8172

3.

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, re-

place the forward clutch drum.

ASSEMBLY OF FORWARD CLUTCH

1.

INSTALL OIL SEAL RINGS
(a)

Coat the three oil seal rings with ATF.

(b)

Contract the oil seal rings as shown, and install

them onto the forward clutch drum.

NOTICE: Do not spread the ring ends more than nec-

essary.

HINT: After installing the oil seal rings, check that they

rotate smoothly.

2.

INSTALL NEW O−RING TO FORWARD CLUTCH DRUM
Coat a new O−ring with ATF and install it on the forward

clutch drum.

3.

INSTALL FORWARD CLUTCH PISTON
(a)

Coat new O−rings with ATF and install them on the

forward clutch piston.

(b)

Being careful not to damage the O−rings, press

the clutch piston into the forward clutch drum with

both hands.

4.

INSTALL PISTON RETURN SPRING
(a)

Install the piston return spring.

AT−72

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AUTOMATIC TRANSMISSION

Component Parts (Forward Clutch)

AT8177

AT1641

Ex. 22R−E

Flange

AT8174

AT2341

Flange

7M−GTE

No.

Thickness

No.

Thickness

61

3.0 (0.118)

44

3.8 (0.150)

60

3.2 (0.126)

42

4.0 (0.157)

45

3.4 (0.134)

63

4.2 (0.165)

62

3.6 (0.142)

64

4.4 (0.173)

D4901 AT3152

SST

(b)

Place SST on the spring retainer, and compress

the return spring with a shop press.

SST

09350−30020 (09350−07040)

(c)

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.

5.

INSTALL CUSHION PLATE ROUNDED END DOWN

AS SHOWN

6.

INSTALL PLATES, DISCS AND FLANGE
(a)

Install in order: P= Plate D= Disc

(22R−E)

P−D−P−D−P−D−P−D

(7M−GTE)

P−D−P−D−P−D−P−D−P−D−P−D

(Others)

P−D−P−D−P−D−P−D−P−D
(b)

And then install the flange, the rounded edge fac-

ing downward.

HINT: There are eight different thickness for the flange.

Flange Thickness

mm (in.)

(c)

Install the snap ring with a screwdriver. Be sure

the end gap of the snap ring is not aligned with

the cutout portion of the forward clutch drum.

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AUTOMATIC TRANSMISSION

Component Parts (Forward Clutch)

AT−73

AT8338

71.2 mm

AT7843

SST

AT8164

7.

CHECK PACK CLEARANCE OF FORWARD CLUTCH
Using SST and a dial indicator, measure the forward

clutch piston stroke applying and releasing the com-

pressed air (4−8 kg/cm

2

, 57 − 114 psi or 392 − 785 kPa)

as shown.

SST

09350−30020 (09350−06120)

Pack clearance:

(22R−E)

0.4 − 0.8 mm (0.016 − 0.031 in.)

(7M−GTE)

0.6 − 1.0 mm (0.024 − 0.039 in.)

(Others)

0.5 − 0.9 mm (0.020 − 0.035 in.)

If the values are nonstandard, inspect the discs.

8.

INSTALL DIRECT CLUTCH ASSEMBLY TO FORWARD

CLUTCH ASSEMBLY
(a)

Make sure that the thrust washer is installed to the

direct clutch drum.

(b)

Align the flukes of discs in the direct clutch.

(c)

Install the direct clutch assembly onto the forward

clutch assembly.

(d)

Check that the distance from the direct clutch end

to the forward clutch end is 71.2 mm (2.803 in.).

If the distance is less than the above value, parts may

have been assembled incorrectly, check and reassemble

again.

AT−74

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AUTOMATIC TRANSMISSION

Component Parts (Forward Clutch)

AT5418

AT5260

AT5462

♦ Non−reusable part

Snap Ring

♦ O−Ring

Second Coast

Brake Band

Cover

E−Ring

E−Ring

Spring

Retainer

Piston

E−Ring

Oil Seal Ring

Piston Rod

Pin

Spring

Second Coast Brake

COMPONENTS

DISASSEMBLY OF SECOND COAST BRAKE

PISTON

1.

REMOVE SECOND COAST BRAKE PISTON OIL

SEAL RING

2.

REMOVE SECOND COAST BRAKE PISTON ROD
(a)

Firmly hold down the piston, then compress the

compression spring.

(b)

Remove the E−ring.

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AUTOMATIC TRANSMISSION

Component Parts (Second Coast Brake)

AT−75

D5634

AT5206

Piston

Spring

Retainer

Piston Rod

AT5260

AT5206

Piston

Spring

Retainer

Piston Rod

AT5205

Printed

Number

(c)

Remove the compression spring, retainer and pis-

ton rod.

INSPECTION OF SECOND COAST BRAKE BAND

INSPECT BRAKE BAND

If the lining of the brake band is peeling off or discolored,

or even if parts of the printed numbers are defaced, re-

place the brake band.

HINT: Before assembling the new band, soak it in ATF

for at least fifteen minutes.

ASSEMBLY OF SECOND COAST BRAKE PISTON

1.

SELECT PISTON ROD
If the band is OK with piston rod stroke not within the

standard value, select the piston rod.

There are two different lengths for piston rod.

Piston rod length: 71.4 mm (2.811 in.)

72.9 mm (2.870 in.)

2.

ASSEMBLE SECOND COAST BRAKE PISTON
(a)

Install the retainer, compression spring and piston to

the piston rod.

(b)

Firmly hold down the piston, then compress the

compression spring.

(c)

Install the E−ring.

AT−76

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AUTOMATIC TRANSMISSION

Component Parts (Second Coast Brake)