Content .. 7 8 9 10 ..

Toyota Automatic Transmission A340 Series. Repair Manual - part 9

AT1979

AT1978

AT8160

AT8151

AT6454

Printed

Number

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:

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

or even if parts of the printed numbers are defaced,

replace all discs.

Before assembling new discs, soak them in ATF for

at least fifteen minutes.

ASSEMBLY OF OVERDRIVE BRAKE

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.

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.

INSTALL PISTON RETURN SPRING
(a)

Install the piston return spring.

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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.

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.

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

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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

Clutch Drum Thrust Washer

Direct Clutch Drum

Direct Clutch Piston

Piston Return Spring

♦ O−Ring

Direct Clutch

COMPONENTS

DISASSEMBLY OF DIRECT CLUTCH

REMOVE DIRECT CLUTCH DRUM ASSEMBLY

FROM FORWARD CLUTCH ASSEMBLY

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AUTOMATIC TRANSMISSION

Component Parts (Direct Clutch)

AT−63

AT8166

SST

AT8167

AT8168

SST

AT8250

AT8154

REMOVE CLUTCH DRUM THRUST WASHER FROM

DIRECT CLUTCH ASSEMBLY

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

, 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.

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

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

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AUTOMATIC TRANSMISSION

Component Parts (Direct Clutch)

AT8169

AT6454

Printed

Number

AT8156

AT8161

AT8435

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

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:

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.

Before assembling new discs, soak them in ATF

for at least fifteen minutes.

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.

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

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.

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AUTOMATIC TRANSMISSION

Component Parts (Direct Clutch)

AT−65

AT1640

Ex. 22R−E

AT8163

AT8443

AT2610

AT8162 AT3152

SST

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.

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

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AUTOMATIC TRANSMISSION

Component Parts (Direct Clutch)

AT3153

AT8153

AT8250

No.

Thickness

No.

Thickness

3.0 (0.118)

3.4 (0.134)

3.1 (0.122)

3.5 (0.138)

3.2 (0.126)

3.6 (0.142)

3.3 (0.130)

3.7 (0.146)

AT8166

SST

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

, 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

INSTALL CLUTCH DRUM THRUST WASHER
Coat the thrust washer with petroleum jelly and install it

onto the direct clutch.

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.

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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

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AUTOMATIC TRANSMISSION

Component Parts (Direct Clutch)

Content .. 7 8 9 10 ..