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Toyota Automatic Transmission A340 Series. Repair Manual - part 33

AT7958

Front

AT7959

E7226

Front

Inside

Outside

Bearing and race

30.5 (1.201)

48.0 (1.890)

AT4932

Inside

Outside

Bearing and race

19.0 (0.748)

45.0 (1.772)

AT4933

mm (in.)

30. INSTALL SUN GEAR TO TRANSFER DIRECT CLUTCH

(a)

Coat the assembled bearing and race with petro-

leum jelly and install it onto the sun gear.

HINT: Assembled bearing and race diameter.

(b)

Install the sun gear into the transfer direct clutch.

HINT: Mesh the splines of the sun gear with the flukes

of the discs by rotating and pushing the sun gear.

31. INSTALL TRANSFER DIRECT CLUTCH WITH SUN

GEAR
(a)

Install the transfer direct clutch with the sun gear.

(b)

Coat the assembled bearing and race with petro-

leum jelly and install it onto the sun gear.

HINT: Assembled bearing and race diameter

(c)

Install the snap ring.

−

AUTOMATIC TRANSMISSION (A340H)

Installation of Component Parts

AT−253

AT7971

Front

AT7960

AT7961

Inside

Outside

Race

23.1 (0.909)

45.0 (1.772)

Inside

Outside

Race

36.3 (1.429)

53.9 (2.122)

AT3171

Flange

AT7972

Front

32. INSTALL OUTPUT SHAFT WITH PLANETARY RING

GEAR
(a)

Coat the races with petroleum jelly and install

them onto the planetary gear and planetary ring

gear.

HINT: Race diameter

mm (in.)

(b)

Install the output shaft with the planetary ring gear.

33. INSTALL FLANGES, PLATES, DISCS AND CUSHION

PLATE OF TRANSFER LOW SPEED BRAKE
(a)

Install the front flange to the case.

(b)

Install the plates and discs.

Install in order: P = Plate D = Disc

D−P−D−P−D−P−D−P−D−P−D−P−D

(c)

Install the rear flange.

AT−254

−

AUTOMATIC TRANSMISSION (A340H)

Installation of Component Parts

AT7963

AT7914

Front

AT7964

AT7965

Inside

Outside

Bearing and race

38.0 (1.496)

57.3 (2.256)

AT8031

mm (in.)

(d)

Install the cushion plate, the rounded end facing

rearward.

34. INSTALL PISTON RETURN SPRING OF TRANSFER

LOW SPEED BRAKE

35. INSTALL TRANSFER CENTER SUPPORT

(a)

Coat the assembled bearing and race with petro-

leum jelly and install it onto the center support.

HINT: Assembled bearing and race diameter

(b)

Install the center support to the case.

HINT: Align the oil holes and bolt hole of the center sup-

port with those of the case side and insert.

(c)

Pushing the center support forward, install the snap

ring.

−

AUTOMATIC TRANSMISSION (A340H)

Installation of Component Parts

AT−255

AT7945

AT7944

AT4935

0.4 mm

(0.016 in.)

3 mm

(0.12 in.)

3.8 (0.150)

4.4 (0.173)

4.0 (0.157)

4.6 (0.181)

4.2 (0.165)

AT4934

AT8030

Flange thickness

mm (in.)

36. CHECK PACK CLEARANCE OF TRANSFER LOW

SPEED BRAKE
Using a feeler gauge, measure the clearance between

the snap ring and flange as shown in the figure.

Clearance: 0.91 − 2.10 mm (0.0358 − 0.0827 in.)

If the piston stroke is less than the limit, parts may have

been assembled incorrectly, check and reassemble

again.

If the piston stroke is nonstandard, select another flange.

HINT: There are five different thicknesses for the flange.

37. INSTALL TRANSFER FRONT DRIVE CLUTCH

(a)

Install the snap ring to the output shaft.

(b)

Install the front drive clutch.

(c)

Install the snap ring.

38. INSTALL FRONT OUTPUT SHAFT

Install the front output shaft into the transfer front drive

clutch.

HINT: Mesh the splines of the front output shaft with

the flukes of the discs by rotating and pushing the front

output shaft.

39. INSTALL TRANSFER CHAIN FRONT CASE

(a)

Clean contacting surfaces of any residual packing

material using gasoline or alcohol.

(b)

Apply seal packing to the transfer case as shown in

the figure.

Seal packing: Part No. 08826 − 00090, THREE BOND

1281 or equivalent

AT−256

−

AUTOMATIC TRANSMISSION (A340H)

Installation of Component Parts

AT4914

AT4917

AT4937

Front

AT7908

1.0 − 1.2 mm

(0.039 − 0.047 in.)

AT4936

(c)

Install the transfer chain front case to the transfer

case.

(d)

Apply sealant to the threads of the bolts.

Sealant:

Part No. 08833 − 00070, THREE BOND

1324 or equivalent

(e)

Install and torque the bolts.

Torque: 345 kg−cm (25 ft−lb, 34 N−m)

40. INSTALL TRANSFER CHAIN OIL RECEIVER

(a)

Apply sealant to the threads of the bolts.

Sealant:

Part No. 08833 − 00070, THREE BOND

1324 or equivalent

(b)

Install the oil receiver to the transfer chain front

case.

(c)

Install and torque the bolts.

Torque: 100 kg−cm (7 ft−lb, 10 N−m)

41. INSTALL DRIVE CHAIN WITH DRIVE SPROCKET

AND DRIVEN SHAFT
(a)

Install the chain with the drive sprocket and driven

shaft.

(b)

Install the snap ring.

42. INSTALL TRANSFER CHAIN REAR CASE

(a)

Clean contacting surfaces of any residual packing

material using gasoline or alcohol.

(b)

Apply seal packing to the chain rear case as shown

in the figure.

Seal packing: Part No. 08826 − 00090, THREE BOND

1281 or equivalent

−

AUTOMATIC TRANSMISSION (A340H)

Installation of Component Parts

AT−257

AT7913

2 − 3 mm

(0.08 − 0.12 in.)

AT7942

AT7981

Front

AT7966

0.4 mm

(0.016 in.)

3 mm (0.12 in.)

AT7943

35 (1.38)

(1.77)

35 (1.38)

mm (in.)

(c)

Install the chain rear case to the front case.

(d)

Install and torque the bolts.

Torque: 345 kg−cm (25 ft−lb, 34 N−m)

HINT: Each bolt length (mm, in.) is indicated in the figure.

43. INSTALL OIL PUMP ASSEMBLY

(a)

Clean contacting surfaces of any residual packing

material using gasoline or alcohol.

(b)

Apply seal packing to the chain rear case as

shown in the figure.

Seal packing:

Part No. 08826 − 00090, THREE

BOND 1281 or equivalent

(c)

Install the oil pump assembly and torque the bolts.

Torque: 160 kg−cm (12 ft−lb, 16 N−rn)

44. INSTALL SPEEDOMETER DRIVE GEAR

45. INSTALL EXTENSION HOUSING

(a)

Clean contacting surfaces of any residual packing

material using gasoline or alcohol.

(b)

Apply seal packing to the extension housing as

shown in the figure.

Seal packing: Part No. 08833 − 00090, THREE BOND

1131, LOCTITE 518 or equivalent

AT−258

−

AUTOMATIC TRANSMISSION (A340H)

Installation of Component Parts

AT7967

SST

AT4285

E7074

AT4938

(1.77)

mm (in.)

(1.77)

(1.89)

AT4231

(c)

Install the extension housing to the chain rear

case.

Torque: 345 kg−cm (25 ft−lb, 34 N−m)

HINT: Each bolt length (mm, in.) is indicated in the fig-

ure.

46. INSTALL REAR COMPANION FLANGE

(a)

Coat a new O−ring with ATF and install it to the

companion flange inner.

(b)

Install the companion flange and washer to the

shaft.

(c)

Using SST to hold the flange, torque a new nut.

SST

09330−00021

Torque: 1,250 kg−cm 190 ft−lb, 123 N−m)

(d)

Using a hammer and punch, stake the nut.

47. INSTALL FRONT COMPANION FLANGE

Install the front companion flange in the same way as the

rear companion flange.

48. INDIVIDUAL PISTON OPERATION INSPECTION

Check for the sound of operation while applying com-

pressed air into the oil hole indicated in the figure.
(1)

Transfer direct clutch

(2)

Transfer low speed brake

(3)

Transfer front drive clutch

If there is no noise, disassemble and check the installa-

tion condition of the parts.

49. INSTALL THROTTLE CABLE

(a)

Coat a new O−ring with ATF and install it to the

cable.

(b)

Install the cable to the case.

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AUTOMATIC TRANSMISSION (A340H)

Installation of Component Parts

AT−259

AT8477

AT4847

Check Ball

Body

E7256

AT7941

23 (0.91)

32 (1.26)

(1.26)

23 (0.91) 32 (1.26)

mm (in.)

Spring

Free length

Outer

diameter

Color

(1)

70.5 (2.776)

19.7 (0.776)

Yellow

(2)

Outer

70.3 (2.768)

20.2 (0.795)

Pink

(3)

Inner

42.1 (1.657)

14.7 (0.579)

Pink

(4)

66.0 (2.598)

16.1 (0.634)

Purple

(5)

Outer

74.6 (2.937)

20.9 (0.823)

Orange

(6)

Inner

46.0 (1.811)

14.0 (0.551)

Yellow

AT8476

50. INSTALL ACCUMULATOR SPRINGS, PISTONS AND

PINS
(a)

Coat new O−rings with ATF and install them to

the pistons.

(b)

Install the five springs, four accumulator pistons

to the bore as shown in the figure.

HINT: The pistons are marked in relief with either C−0,

B−0, C−2, B−2 to differentiate between them.

S Spring

mm (in.)

51. INSTALL CHECK BALL BODY AND SPRING

52. INSTALL TRANSMISSION VALVE BODY

(a)

Align the groove of the manual valve to the pin of

the lever.

(b)

Connect the throttle cable to the cam.

(c)

Confirm the springs into the accumulator pistons

are installed correctly.

(d)

Install the sixteen bolts.

HINT: Each bolt length (mm, in.) is indicated in the fig-

ure.

Torque: 100 kg−cm (7 ft−lb, 10 N−m)

AT−260

−

AUTOMATIC TRANSMISSION (A340H)

Installation of Component Parts

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