Toyota Automatic Transmission A340 Series. Repair Manual — part 9
AT1979
AT1978
AT8160
AT8151
AT6454
Printed
Number
5.
REMOVE OIL SEAL RINGS
INSPECTION OF OVERDRIVE BRAKE
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 defaced,
replace all discs.
S
Before assembling new discs, soak them in ATF for
at least fifteen minutes.
ASSEMBLY OF OVERDRIVE BRAKE
1.
INSTALL OIL SEAL RINGS
(a)
Coat the two oil seal rings with ATF.
(b)
Contract the oil seal rings as shown, and install
them onto the O/D support.
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 OVERDRIVE BRAKE PISTON
(a)
Coat two new O−rings with ATF and install them on
the O/D brake piston.
(b)
Being careful not to damage the O−rings, press in
the brake piston into the O/D support with both
hands.
3.
INSTALL PISTON RETURN SPRING
(a)
Install the piston return spring.
−
AUTOMATIC TRANSMISSION
Component Parts (Overdrive Brake)
AT−61
AT8158
AT8149
AT8152
SST
(b)
Place SST on the spring retainer, and compress
the return spring with a shop press.
SST
09350−30020 (09350−07030)
(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 O/D support.
4.
INSTALL CLUTCH DRUM THRUST WASHER
Coat the thrust washer with petroleum jelly and install it
onto the O/D support.
HINT: Make sure that the lug shape matches the hole
on the O/D support.
5.
CHECK OVERDRIVE BRAKE PISTON MOVEMENT
(a)
Place the O/D support assembly onto the direct
clutch assembly.
(b)
Apply compressed air into the oil passage as
shown, and be sure that the O/D brake piston
moves smoothly.
AT−62
−
AUTOMATIC TRANSMISSION
Component Parts (Overdrive Brake)
AT8153
♦ Non−reusable part
AT6390
Plate
Flange
S SUPRA
S CRESSIDA
Plate
Disc
Snap Ring
Flange
S TRUCK
S 4 RUNNER
3VZ−E
Disc
Snap Ring
Snap Ring
Clutch Drum Thrust Washer
Direct Clutch Drum
Direct Clutch Piston
Piston Return Spring
♦ O−Ring
Direct Clutch
COMPONENTS
DISASSEMBLY OF DIRECT CLUTCH
1.
REMOVE DIRECT CLUTCH DRUM ASSEMBLY
FROM FORWARD CLUTCH ASSEMBLY
−
AUTOMATIC TRANSMISSION
Component Parts (Direct Clutch)
AT−63
AT8166
SST
AT8167
AT8168
SST
AT8250
AT8154
2.
REMOVE CLUTCH DRUM THRUST WASHER FROM
DIRECT CLUTCH ASSEMBLY
3.
CHECK PISTON STROKE OF DIRECT CLUTCH
(a)
Place the direct clutch assembly onto the O/D
support assembly.
(b)
Using SST and a dial indicator, measure the di-
rect clutch piston stroke, applying and releasing
the compressed air (4 − 8 kg/cm
2
, 57 − 114 psi or
392 − 785 kPa) as shown.
SST
09350−30020 (09350−06120)
Piston stroke:
22R−E 1.03 − 1.33 mm (0.0405 − 0.0524 in.)
Others 1.37 − 1.60 mm (0.0359 − 0.0630 in.)
If the values are nonstandard, inspect the discs.
4.
REMOVE FLANGE, PLATES AND DISCS
(a)
Remove the snap ring from the direct clutch drum.
(b)
Remove the flange, plates and discs
(22R−E)
One flange, three plates and three discs
(Others)
One flange, four plates and four discs
5.
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−64
−
AUTOMATIC TRANSMISSION
Component Parts (Direct Clutch)
AT8169
AT6454
Printed
Number
AT8156
AT8161
AT8435
6.
REMOVE DIRECT CLUTCH PISTON
(a)
Place the direct clutch drum onto the O/D support.
(b)
Hold the direct clutch piston with hand, apply com-
pressed air to the O/D support to remove the di-
rect clutch piston.
(c)
Remove the direct clutch piston.
(d)
Remove the two O−rings from the piston.
INSPECTION OF DIRECT 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 DIRECT 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.
3.
CHECK DIRECT CLUTCH DRUM BUSHING
Using a dial indicator, measure the inside diameter of
the clutch drum bushing.
Maximum inside diameter: 53.99 mm (2.1256 in.)
If the inside diameter is greater than the maximum, re-
place the clutch drum.
ASSEMBLY OF DIRECT CLUTCH
1.
INSTALL DIRECT CLUTCH PISTON TO DIRECT
CLUTCH DRUM
(a)
Coat new O−rings with ATF and install them on
the direct clutch piston.
(b)
Being careful not to damage a O−rlngs, press in
the direct clutch piston into the clutch drum with
both hands.
−
AUTOMATIC TRANSMISSION
Component Parts (Direct Clutch)
AT−65
AT1640
Ex. 22R−E
AT8163
AT8443
AT2610
AT8162 AT3152
SST
2.
INSTALL PISTON RETURN SPRING
(a)
Install the piston return spring.
(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.
3.
INSTALL PLATES, DISCS AND FLANGE
(a)
Install the plates and discs.
Install in order: P =Plate D =Disc
(22R−E)
P−D−P−D−P−D
(Others)
P−D−P−D−P−D−P−D
(b)
Install the flange, the flat end facing downward.
(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 direct clutch drum.
AT−66
−
AUTOMATIC TRANSMISSION
Component Parts (Direct Clutch)
AT3153
AT8153
AT8250
No.
Thickness
No.
Thickness
33
3.0 (0.118)
29
3.4 (0.134)
32
3.1 (0.122)
28
3.5 (0.138)
31
3.2 (0.126)
27
3.6 (0.142)
30
3.3 (0.130)
34
3.7 (0.146)
AT8166
SST
4.
CHECK PISTON STROKE OF DIRECT CLUTCH
(a)
Place the direct clutch assembly onto the O/D
support assembly.
(b)
Using SST and a dial indicator, measure the direct
clutch piston stroke applying and releasing the
compressed air (4 − 8 kg/cm
2
, 57 − 114 psi or 392
− 785 kPa) as shown.
SST
09350−30020 (09350−06120)
Piston stroke:
22R−E 1.03 − 1.33 mm (0.0405 − 0.0524 in.)
Others 1.37 − 1.60 mm (0.0539 − 0.0630 in.)
If the piston stroke is less than the limit, parts may have
been assembled incorrectly, so check and reassemble
again.
If the piston stroke is nonstandard, select another flange.
HINT: There are eight different thicknesses for the flange.
mm (in.)
Flange thickness
5.
INSTALL CLUTCH DRUM THRUST WASHER
Coat the thrust washer with petroleum jelly and install it
onto the direct clutch.
6.
INSTALL DIRECT CLUTCH ASSEMBLY TO FORWARD
CLUTCH ASSEMBLY
(a)
Align the flukes of discs in the direct clutch.
(b)
Install the direct clutch assembly onto the forward
clutch assembly.
−
AUTOMATIC TRANSMISSION
Component Parts (Direct Clutch)
AT−67
AT8338
71.2 mm
(c)
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−68
−
AUTOMATIC TRANSMISSION
Component Parts (Direct Clutch)
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