Toyota Automatic Transmission A340 Series. Repair Manual - part 7

AT1636

AT8225

AT8236

AT8334

SST

(i)

Insert SST behind No. 1 brake piston and gradu-

ally lift it out of the transmission case.

SST

09350−30020 (09350−07090)

(j)

Remove the two O−rings from No. 1 piston.

40. REMOVE MANUAL VALVE LEVER, SHAFT AND OIL

SEALS
(a)

Using a chisel, cut off the spacer and remove it

from the shaft.

(b)

Using a pin punch, drive out the pin.

(c)

Pull the manual valve lever shaft out through the

case and remove the lever.

(d)

Using a screwdriver, remove the two oil seals.

AT−45

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AUTOMATIC TRANSMISSION (A340E)

Removal of Component Parts

COMPONENT PARTS

General Notes

The instructions here are organized so that you work on only one 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.

As much as possible, complete the inspection, repair and assembly before proceeding to the next

component group. If a component group can not be assembled because parts are being ordered,

be sure to keep all parts of that group in a separate container while proceeding with disassembly,

inspection, repair and assembly of other component groups.

Recommended ATF: DEXRONR II
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 prevent acciden-

tally spraying automatic transmission fluid or kerosene on your face.

3.

The recommended automatic transmission fluid or kerosene should be used for cleaning.

PARTS ARRANGEMENT:

1.

After cleaning, the parts should be arranged in proper order to allow efficient inspection, re-

pairs, and reassembly.

2.

When disassembling a valve body, be sure to keep each valve together with the correspond-

ing spring.

3.

New discs for the brakes and clutches that are to be used for replacement must be soaked

in transmission fluid for at least fifteen minutes before assembly.

GENERAL ASSEMBLY:

1.

All oil seal rings, clutch discs, clutch plates, rotating parts, and sliding surfaces should be

coated with transmission fluid prior to reassembly.

2.

All gaskets and rubber O−rings should be replaced.

3.

Make sure that the ends of a snap ring are not aligned with one of the cutouts and are

installed in the groove correctly.

4.

If a worn bushing is to be replaced, the subassembly containing that bushing must also be

replaced.

5.

Check thrust bearings and races for wear or damage. Replace if necessary.

6.

Use petroleum jelly to keep parts in place.

AT−46

−

AUTOMATIC TRANSMISSION

Component Parts (General Notes)

AT8413

Torque Converter

AT8412

AT5461

♦ Non−reusable part

kg−cm (ft−lb, N−m)

: Specified torque

♦ Oil Seal

♦ O − Ring

Oil Seal Ring

Oil Pump Drive Gear

Oil Pump Driven Gear

Stator Shaft

100 (7, 10)

Oil Pump Body

Oil Pump

COMPONENTS

DISASSEMBLY OF OIL PUMP

1.

USE TORQUE CONVERTER AS WORK STAND
Place the oil pump body on the torque converter.

2.

REMOVE OIL SEAL RINGS
Remove the two oil seal rings.

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AUTOMATIC TRANSMISSION

Component Parts (Oil Pump)

AT−47

AT0153

Driven Gear

AT0154

AT0155

AT5271

AT8411

3.

REMOVE STATOR SHAFT
(a)

Remove the thirteen bolts, and then remove the

stator shaft from the oil pump body.

(b)

Remove the oil pump body from the torque con-

verter.

4.

CHECK BODY CLEARANCE OF DRIVEN GEAR
Push the driven gear to one side of the body.

Using a feeler gauge, measure the clearance.

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-

place the drive gear, driven gear or pump body.

5.

CHECK TIP CLEARANCE OF DRIVEN GEAR
Measure between the driven gear teeth and the cres-

cent−shaped part of the pump body.

Standard tip clearance: 

0.11 − 0.14 mm

(0.0043 − 0.0055 in.)

Maximum tip clearance: 

0.3 mm (0.012 in.)

If the tip clearance is greater than the maximum, re-

place the drive gear, driven gear or pump body.

6.

CHECK SIDE CLEARANCE OF BOTH GEARS
Using a steel straight edge and feeler gauge, measure

the side 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, re-

place the drive gear, driven gear or pump body.

7.

REMOVE OIL PUMP DRIVE GEAR AND DRIVEN

GEAR

AT−48

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AUTOMATIC TRANSMISSION

Component Parts (Oil Pump)

AT5357

AT5152

AT5153

AT5154

SST

8.

REMOVE OIL SEAL
(a)

Pry off the oil seal with a screwdriver.

(b)

Using SST, install a new oil seal.

The oil seal end should be flush with the outer edge of

the pump body.

SST

09350−30020 (09351−32140)

(c)

Coat the oil seal lip with MP grease.

CHECK OIL PUMP BUSHING

1.

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 (1.5035 in.)

If the inside diameter is greater than the maximum, re-

place the oil pump body.

2.

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, re-

place the stator shaft.

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AUTOMATIC TRANSMISSION

Component Parts (Oil Pump)

AT−49

AT8409

AT8410

AT8408

AT5358

ASSEMBLY OF OIL PUMP

1.

INSTALL DRIVEN GEAR AND DRIVE GEAR TO OIL

PUMP BODY
(a)

Place the oil pump body on the torque converter.

(b)

Coat the driven gear and drive gear with ATF.

(c)

Install the driven gear and drive gear.

2.

INSTALL STATOR SHAFT TO OIL PUMP BODY
(a)

Align the stator shaft with each bolt hole.

(b)

Tighten the thirteen bolts.

Torque: 100 kg−cm (7 ft−lb, 10 N−m)

3.

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 stator shaft.

NOTICE: Do not spread the ring ends too much.

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

rotate smoothly.

4.

CHECK OIL PUMP DRIVE GEAR ROTATION
Make sure the drive gear rotates smoothly.

AT−50

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AUTOMATIC TRANSMISSION

Component Parts (Oil Pump)

AT8130

AT3150

♦ Non−reusable part

O/D Planetary

Ring Gear

Snap Ring

Race

Ring Gear

Flange

Snap Ring

O/D One−Way

Clutch

Retaining

Plate

One−Way Clutch

Outer Race

Bearing

Bearing

O/D Planetary Gear

Thrust Washer

♦ O−Ring

Snap Ring

Plate

Snap Ring

Race

Piston Return Spring

O/D Direct Clutch Piston

Ex. A340F

O/D Direct Clutch Drum

Flange

Disc

AT8138

Hold

Turn

Lock

Free

Overdrive Planetary Gear, Overdrive Direct Clutch and

Overdrive One−Way Clutch

COMPONENTS

DISASSEMBLY OF OVERDRIVE PLANETARY

GEAR, OVERDRIVE DIRECT CLUTCH AND

OVERDRIVE ONE−WAY CLUTCH

1.

CHECK OPERATION OF ONE−WAY CLUTCH
Hold the O/D direct clutch drum and turn the input shaft.

The input shaft turns freely clockwise and locks counter-

clockwise.

2.

REMOVE OVERDRIVE DIRECT CLUTCH ASSEMBLY

FROM OVERDRIVE PLANETARY GEAR

−

AUTOMATIC TRANSMISSION

Component Parts (Overdrive Planetary Gear, Overdrive

Direct Clutch and Overdrive One−Way Clutch)

AT−51

AT4448

Vinyl Tape

SST

AT8131

AT8132

SST

AT3151

AT8140

3.

CHECK PISTON STROKE OF OVERDRIVE DIRECT

CLUTCH
(a)

Place the oil pump onto the torque converter, and

then place the O/D direct clutch assembly onto

the oil pump.

(b)

Using SST and a dial indicator, measure the O/D

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: 1.77 − 2.07 mm (0.0697 − 0.0815 in.)

Others: 1.85 − 2.15 mm (0.0728 − 0.0846 in.)

If the values are nonstandard, inspect the discs.

4.

REMOVE FLANGE, PLATE(S) AND DISC(S)
(a)

Remove the snap ring from the O/D direct clutch

drum.

(b)

Remove the flange, plates and discs.

HINT:  

22R−E: One flange, one plate and one disc

Others: One flange, two plates and two 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.

6.

REMOVE OVERDRIVE DIRECT CLUTCH PISTON
(a)

Place the oil pump onto the torque converter and

then place the O/D direct clutch onto the oil pump.

(b)

Hold the O/D direct clutch piston with hand, apply

compressed air to the oil pump to remove the O/D

direct clutch piston.

(c)

Remove the O/D direct clutch piston.

(d)

Remove the two O−rings from the piston.

AT−52

−

AUTOMATIC TRANSMISSION

Component Parts (Overdrive Planetary Gear, Overdrive

Direct Clutch and Overdrive One−Way Clutch)