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Torque Converter Transmission

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0% found this document useful (0 votes)
129 views36 pages

Torque Converter Transmission

Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PDF, TXT or read online on Scribd
You are on page 1/ 36

2-1

TORQUE CONVERTER & TRANSMISSION


Page
GENERAL .......................................................................... 2-2
HYDRAULIC CIRCUIT DIAGRAM ................................. 2-5
SPECIFICATIONS ............................................................ 2-6 2
COMPONENTS ................................................................ 2-7
TROUBLESHOOTING .................................................... 2-13
TRANSMISSION & CONTROL VALVE ASSY ........... 2-14
REMOVAL•INSTALLATION ................................................. 2-14
DISASSEMBLY•INSPECTION •REASSEMBLY .................... 2-15
TORQUE CONVERTER• OIL PUMP ............................ 2-18
REMOVAL •INSTALLATION................................................. 2-18
TORQUE CONVERTER & TRANSMISSION
ASSY ................................................................................ 2-21
REMOVAL•INSTALLATION ................................................. 2-21
TRANSMISSION ASSY ................................................... 2-24
DISASSEMBLY•INSPECTION •REASSEMBLY .................... 2-24
CLUTCH DRUM ASSY .................................................... 2-31
DISASSEMBLY•INSPECTION •REASSEMBLY .................... 2-31
DIRECTION SWITCH ASSY .......................................... 2-34
REMOVAL•INSTALLATION ................................................. 2-34
OIL PRESSURE MEASUREMENT AND
STALL TEST .................................................................. 2-35
2-2

GENERAL

F R

F: Forward
R: Reverse
2-3

Control Valve (Upper)

2
D D

C C

B B

A A

A-A: Accumulator

B-B: Change valve

C-C: Inching valve

D-D: Regulator valve


2-4

Control Valve (Lower)

C C

B B

A A

A-A: Shift change valve (R)

B-B: Shift change valve (F)

C-C: Safety valve


Accumulator

Solenoid valve (F)

Shift change valve (F) Inching valve


HYDRAULIC CIRCUIT DIAGRAM

Safety
valve

Regulator valve

In-line strainer

Relief
Shift change valve
valve (R)

Oil pump
Cooler

F clutch R clutch Oil


Solenoid valve (R)
filter
2-5

2
2-6

SPECIFICATIONS
Maker Aisin

Torque converter type 3 elements, 1 stage, 2 phases type

Torque converter model AISIN

Stall torque ratio 4Y•1DZ-II : 2.68


2Z : 2.72

Stall speed rpm 4Y•1DZ-II : 2100


2Z : 2050

Control system Solenoid type selector valve

Clutch operating pressure


1108 (11.3) [161]
(main pressure) kPa(kgf/cm2)[psi]

Torque converter
392 (4.0) [57]
outlet pressure kPa(kgf/cm2)[psi]

Torque converter
9.0 (2.38)
oil capacity (USgal)

Torque converter oil ATF GM Dexron II

Note: The indicated oil pressure is at an engine speed of 2000 rpm.

Torque Converter Ratio

1 ton series 2 •3• J3.5 ton series

4Y•1DZ-II 4Y•1DZ-II 2Z

Forward 1.531 1.583 1.340

Reverse 1.540 1.594 1.343


2-7

COMPONENTS
Torque Converter Housing

3201

3201-166

Torque Converter

3202
2-8

Torque Converter Clutch

3203
2-9

Torque Converter Gear

3204

3
2-10

Control Valve

3206
2-11

Torque Converter Piping

3213

3
2-12

Direction Switch

5701
Disassembly and inspection
Components other than control On-board inspection
Control valve valves (torque converter &
transmission)

Regulator valve
Inching valve
Shift change valve for F
Shift change valve for R
Safety valve
Change valve for F↔R
Accumulator for F, R
Solenoid valve For F
Solenoid valve for R
In-line strainer
Relief valve
Wire to solenoid
Oil strainer
Torque converter
Oil pump
Clutch drum for F
Clutch drum for R
Gear, bearing
Shift lever switch and
neutral start switch
ATF level and quality
Inching lever, and wire cable
Oil pressure test
Stall test

Faulty starting No starting at F


TROUBLESHOOTING

No starting at R

No starting at any ranges

Start at N range

Changed naturally from F

Large shock at starting At N → F


(shifting) At starting after
shifting
At N → R

At F
Inching
start
At R

Large time lag at starting At N → F


(shifting)
At N → R

At switch back F↔R

Slippage At F

At R

Others Starter fails to revolve at N.

Starter revolves at ranges other than N.

No inching operation

Overheating of transmission, no air flow


from breather

Abnormal noise
2-13

3
2-14

TRANSMISSION & CONTROL VALVE ASSY


REMOVAL•INSTALLATION T = N•m (kgf-cm) [ft-lbf]

*T = 9.6 ~ 14.4
(98 ~ 145)
5 [7.09 ~ 10.5]
T = 9.81 ~ 15.7
(100 ~ 160)
[7.24 ~ 11.6]

3
2

*: Note that only this bolt is M6 in the 1 speed torque converter and that all other bolts are different in size (M8 bolts).

Removal Procedure
1 Remove the toe board.

2 Disconnect the inching wire.

3 Disconnect the electrical wiring.

4 Disconnect the torque converter cooler hose.

5 Remove the transmission cover & control valve ASSY.

Installation Procedure
The installation procedure is reverse of the removal procedure.
2-15

DISASSEMBLY•INSPECTION •REASSEMBLY T = N•m (kgf-cm) [ft-lbf]

T = 5.3 ~ 9.4 T = 9.8 ~ 15.7


(54 ~ 96) (100 ~ 160)
[3.9 ~ 6.9] [7.2 ~ 11.6]

T = 5.3 ~ 9.4
(54 ~ 96)
[3.9 ~ 6.9]

T = 14.9 ~ 22.3
(152 ~ 227)
[11.0 ~ 16.4]

Disassembly Procedure
1 Disconnect the solenoid valve connector.

2 Remove the solenoid valve.

3 Remove the sleeve lock plate and solenoid wire ASSY.

4 Remove the inching lever.

5 Remove the inching lever oil seal. [Point 1]

6 Remove the accumulator valve, inching valve and regulator valve. [Point 2]

7 Remove the change valve lock plate and pin. [Point 3]

8 Remove the change valve.

9 Remove the lower valve body ASSY, oil strainer, steel ball and spring. [Point 4]

10 Remove the safety valve, F shift valve and R shift valve. [Point 5]
2-16

Reassembly Procedure
The reassembly procedure is reverse of the disassembly procedure.

Point Operations
SST
[Point 1]
Reassembly:
SST SST 09950-60010 ---
09950-70010 ---

[Point 2]
Disassembly:
Remove the valve plug using the service bolt.

Service bolt size: M8 x 1.25

Inspection:
Measure free length of each valve spring.
Standard mm (in) Limit mm (in)
Accumulator valve (inner) 86.0 (3.386) 81.7 (3.217)
Accumulator valve (outer) 117.0 (4.606) 111.2 (4.378)
Inching valve (plug side) 70.3 (2.768) 66.8 (2.630)
Inching valve (valve side) 49.9 (1.965) 47.4 (1.866)
Regulator valve 88.8 (3.496) 84.4 (3.323)

[Point 3]
Disassembly:
1st Speed
1. Remove the pin.
2. Remove the valve plug using the service bolt.

Service bolt size: M6 x 1.0


2-17

[Point 4]
Reassembly:
Install the lower valve body.
1. Install the oil strainer, spring and steel ball on the lower
valve body, and put the plate and gasket on top.
2. Reverse the above while maintaining the assembled state
and install it on the transmission cover.

[Point 5]
Disassembly:
Press in the valve plug with its opening facing downwards
and remove the key.

Inspection:
Measure free length of each valve spring.

Standard mm (in) Limit mm (in)


F/R shift valve 53.5 (2.106) 50.8 (2.000)
Safety valve 59.8 (2.354) 56.8 (2.236)
2-18

TORQUE CONVERTER• OIL PUMP


REMOVAL•INSTALLATION T = N•m (kgf-cm) [ft-lbf]

T = 9.81 ~ 18.6
(100 ~ 190)
[7.24 ~ 13.7]

3
4

Removal Procedure
1 Drain the torque converter oil.

2 Remove the engine. (See page 1-8.)

3 Remove the torque converter ASSY. [Point 1]

4 Remove the oil pump with stator shaft. [Point 2]

5 Remove the stator shaft.

6 Remove the oil pump gear. [Point 3]

7 Remove the oil seal. [Point 4]

Installation Procedure
The installation procedure is reverse of the removal procedure.
2-19

Point Operations
Seal ring [Point 1]
Removal:
Be careful as the torque converter ASSY contains oil.
Installation:
Apply grease before installing the seal ring and oil seal lip.
Installation:
Install while rotating the torque converter ASSY so that the
Oil seal
extension nail enters into the groove in the oil pump drive
gear.

[Point 2]
Removal:
SST 09950-50012
3
SST

[Point 3]
Inspection:
Measure clearance between the oil pump driven gear and
pump body.

Limit: 0.3 mm (0.012 in)

Inspection:
Measure clearance between the oil pump driven gear and
crescent.

Limit: 0.4 mm (0.016 in)

Inspection:
Measure clearance between the oil pump drive gear and
crescent.

Limit: 0.4 mm (0.016 in)


2-20

Inspection:
Measure clearance between the pump body and each gear.

Limit: 0.1 mm (0.004 in)

Inspection:
Measure clearance between the oil pump drive gear bush-
ing and stator shaft.

Limit: 0.15 mm (0.0059 in)

[Point 4]
Installation:
SST SST 09950-60020 ---
09950-70010 ---
SST
2-21

TORQUE CONVERTER & TRANSMISSION ASSY


REMOVAL•INSTALLATION T = N•m (kgf-cm) [ft-lbf]

Engine mounting nut T = 53.9 ~ 99.0 (550 ~ 1010) [39.8 ~ 73.1]


Torque converter mounting set bolt T = 49.0 ~ 78.5 (500 ~ 800) [36.2 ~ 57.9]
Torque converter housing set bolt T = 29.4 ~ 44.1 (300 ~ 450) [21.7 ~ 32.6]
Gasoline model:
T = 56.9 ~ 64.7 (580 ~ 660) [42.0 ~ 47.8]
Drive plate set bolt (for connecting to engine crankshaft)
Diesel model:
T = 76.5 ~ 93.2 (780 ~ 950) [56.4 ~ 68.7]
Drive plate set bolt (for connecting to torque converter) T = 14.7 ~ 21.6 (150 ~ 220) [10.9 ~ 15.9]
2-22

Removal Procedure
1 Remove the engine hood. (See page 9-5.)

2 Remove the toe board.

3 Drain the coolant.

4 Remove the battery and battery tray.

5 Diesel Vehicle:
Remove the sedimenter bracket set bolt to make the bracket free.

6 Disconnect the accelerator wire and fuel hose. [Point 1]

7 Remove fuse box and electrical parts plate set bolts to set them free.

8 Disconnect connectors and wiring harnesses from the engine.

9 Remove the horn with bracket.

10 Disconnect the inching wire.

11 Disconnect the torque converter cooler hose. [Point 2]

12 Remove the radiator.

13 Disconnect the air cleaner hose.

14 Remove the oil pump set bolts to set the pump free.

15 Disconnect the exhaust pipe.

16 Remove the under cover.

17 Remove the propeller shaft. (See page 3-3.)

18 Remove the transmission mounting bolts.

19 Remove the engine mounting nuts.

20 Remove the engine with torque converter. [Point 3]

21 Remove the cover plate.

22 Remove the drive plate set bolts. [Point 4]

23 Separate the engine from the torque converter housing.

24 Remove the transmission cover and control valve ASSY.

Installation Procedure
The installation procedure is reverse of the removal procedure.
2-23

Point Operations
[Point 1]
Removal:
Put match marks on the fuel hose and the mating joint.

[Point 2]
Removal:
Put match marks on the radiator and torque converter cooler
hose. 3

[Point 3]
Removal • installation:
SST SST 09010-20111-71 ---
SST 09010-23320-71 ---
Move the SST hook position to adjust the balance.

[Point 4]
Removal • Installation:
Turn the flywheel using the crankshaft pulley set bolt.
2-24

TRANSMISSION ASSY
DISASSEMBLY•INSPECTION •REASSEMBLY T = N•m (kgf-cm) [ft-lbf]

14
T = 7.8 ~ 17.6
(80 ~ 180)
[5.8 ~ 13.0]
2

T = 5.9 ~ 7.8 (60 ~ 80)


[4.34 ~ 5.79]
15

15

T = 9.81 ~ 15.7
(100 ~ 160)
3 [7.24 ~ 11.6] 16
7
9

T = 9.81 ~ 18.6
(100 ~ 190)
[7.24 ~ 13.8]

16

9
11
12

12

13 4
2-25

Disassembly Procedure
1 Drain the torque converter oil.

2 Remove the torque converter.

3 Remove the oil pump with stator shaft and shim. [Point 1]

4 Remove the output shaft with front bearing case and the shim. [Point 2]

5 Disassemble the output shaft with front bearing case. [Point 3]

6 Remove the counter gear shaft.

7 Remove the main shaft ASSY. [Point 4]

8 Remove the spacer, rear bearing, reverse clutch gear, forward clutch gear and reverse & forward
clutch drum ASSY. [Point 5]
(For disassembly, inspection and reassembly of the clutch drum ASSY, see page 2-31.)

9 Remove the reverse and forward clutch gear bearings. [Point 6]

10 Remove the bearing spacer from the output gear portion. [Point 7]

11 Remove the counter gear.

12 Remove the counter gear bearing. [Point 8]

13 Remove the output gear.

14 Remove the oil filter. [Point 9]

15 Remove the oil pan and oil strainer. [Point 10]

16 Remove the main shaft front bearing and output shaft rear bearing. [Point 11]

Reassembly Procedure
The reassembly procedure is reverse of the disassembly procedure.
2-26

Point Operations
[Point 1]
Disassembly:
SST SST 09950-50012

Reassembly:
Tentatively install the oil pump with stator shaft and check
the main shaft thrust clearance.
Standard: 0.20 to 0.62 mm (0.0079 to 0.0244 in)
If the measured clearance fails to fall within the specified
range, increase or decrease the shim thickness for adjust-
ment.

Shim Mark Thickness mm (in)


0 0.67 ~ 0.75 (0.026 ~ 0.030)
1 0.855 ~ 0.945 (0.034 ~ 0.037)
2 1.065 ~ 1.175 (0.042 ~ 0.046)
3 1.335 ~ 1.465 (0.053 ~ 0.058)

[Point 2]
Disassembly:
Remove the output shaft with front bearing case using the
service bolt.
Service bolt size: M10 x 1.25

Reassembly:
Check the output shaft thrust clearance.
Standard: 0.03 to 0.51 mm (0.0012 to 0.0200 in)
If the measured clearance fails to fall within the specified
range, increase or decrease the shim thickness for adjust-
ment.

Mark Thickness mm (in)


Shim 0 0.855 ~ 0.945 (0.034 ~ 0.037)
1 1.190 ~ 1.310 (0.047 ~ 0.052)
2 1.530 ~ 1.670 (0.060 ~ 0.066)

[Point 3]
Disassembly:
Disassemble the output shaft front bearing case.
1. Remove the snap ring using the SST.
SST 09905-00012
2. Remove the output shaft using a plastic hammer.
3. Remove the oil seal using a straight-edge screwdriver.
2-27

4. Remove the front bearing using the SST.


SST 09950-60010 ---
09950-70010 ---
SST 5. Remove the dust deflector using a screwdriver.

SST

Reassembly:
Install the output shaft front bearing case.
SST
SST 1. Install the dust deflector using the SST.
SST 09316-60011 3
2. Install the front bearing using the SST.
SST SST 09950-60020 ---
09950-70010 ---

3. Install the oil seal using the SST.


SST 09150-10170-71
4. Install the output shaft using a plastic hammer.
SST

5. Install the snap ring using the SST.


SST 09905-00012

[Point 4]
Disassembly • Reassembly:
Remove or install components while supporting them from
disconnection or falling down.

Reassembly:
Apply grease to the seal ring at the tip of main shaft before
reassembly.
2-28

[Point 5]
Inspection:
Measure side clearance of the seal ring.

Limit: 0.2 mm (0.008 in)

Reassembly:
Trrce up the clutch disc serrations with a screwdriver and
then install the clutch gear.

[Point 6]
Disassembly:
SST SST 09950-60020 ---
09950-70010 ---

SST

Reassembly:
SST 09950-60020 ---
09950-70010 ---
SST

SST

[Point 7]
Reassembly:
Install the baring spacer.
1. Tentatively secure the bearing spacer by bringing the out-
put gear towards the output shaft.
2. Secure it from the outside by a screwdriver to protect it
from falling down.
2-29

[Point 8]
Disassembly:
SST 09320-23000-71
SST

Reassembly:
SST 09950-60020 ---
SST 09950-70010 ---
3
SST

[Point 9]
Disassembly-Reassembly:
SST 09228-07501

SST

[Point 10]
Reassembly:
Remove iron chips adhering on the magnet and locate the
magnet as shown.

Magnet

[Point 11]
Disassembly:
SST 09320-23000-71

SST
2-30

Reassembly:
SST
SST 09950-60020 ---
09950-70010 ---

SST

Clutch operation check after reassembly


Blow air through the oil hole on top of the transmission case
F
and see that each clutch piston is operated.

F
R
2-31

CLUTCH DRUM ASSY


DISASSEMBLY•INSPECTION •REASSEMBLY
3

2 1

Disassembly Procedure
1 Remove the snap ring.

2 Remove the backing plate, clutch disc, clutch plate and camber plate. [Point 1]

3 Remove the snap ring and clutch piston return spring. [Point 2]

4 Remove the clutch piston. [Point 3]

Reassembly Procedure
The reassembly procedure is reverse of the disassembly procedure.
2-32

[Point 1]
Inspection:
Measure the clutch disc thickness.

Standard: 2.6 mm (0.102 in)


Limit: 2.3 mm (0.091 in)

Inspection:
Measure thickness of the clutch plate.

Standard: 2.0 mm (0.079 in)


Limit: 1.8 mm (0.071 in)

Inspection:
Measure height of the camber plate curving.

Standard: 3.4 mm (0.134 in)


Limit: 3.1 mm (0.122 in)

Reassembly:
Clutch gear side
Install the camber plate to the clutch drum, with punched
mark A facing up.

Reassembly:
Install the clutch plate and clutch disc alternately on the
clutch drum, while applying torque converter oil.

Number of clutch discs


Piston side
1 ton series 4Y and 1DZ-II models 4
4Y and 1DZ-II models 5
2• 3 ton series
2Z model 5
4Y model 5
J3.5 ton series
2Z model 5

Camber plate
2-33

Reassembly:
Adjust the clearance between the backing plate and clutch
disc.
1. Install the camber plate, clutch plate, clutch disc, back-
ing plate and snap ring on the clutch drum.
2. Measure clearance between the backing plate and clutch
disc using thickness gauges.
Standard:
4-disc specification: 0.8 to 1.3 mm (0.031 to 0.051 in)
5-disc specification: 1.0 to 1.6 mm (0.039 to 0.063 in)

3. If the measured value is out of the specified range, se-


lect a suitable backing plate.
Backing plate thickness: A = 3.0, 3.5 and 4.0 mm
(0.118, 0.138 and 0.157 in) 3
A

[Point 2]
Disassembly • Reassembly:
Compress the return spring using the SST and remove or
install the snap ring.
Tie two hooks of the SST by a wire or string as shown and
secure the hooks so that they will not disconnected from
SST the clutch drum.
SST 09220-22001-71

Caution:
If the hooks are disconnected from the clutch drum while
the SST is in use, spring will jump out, which is danger-
ous.

Inspection:
Measure free length of the clutch piston return spring.

Standard: 63.4 mm (2.496 in)


Limit: 58.5 mm (2.303 in)

[Point 3]
Disassembly:
Pinch the rib of clutch piston by pliers with cloth in-between
and remove the piston.
2-34

DIRECTION SWITCH ASSY


REMOVAL•INSTALLATION

Removal Procedure
1 Remove the turn signal switch cover.
2 Disconnect the wiring.
3 Remove the direction switch ASSY. [Point 1]

Installation Procedure
The installation procedure is reverse of the removal procedure.
Point Operations
[Point 1]
Inspection:
Check electrical continuity between switch connector ter-
minals.
(P: Position, T: Terminal No., — : Continuous)
LH spec. (STD) RH spec. (OPT)
1 : VR 1: T N IG1 IG2 VF VF2 ST VR Ra
2 : Ra 2 : IG2 P
3 : ST 3:N F1
4 : VF2 4 : IG1
5 : VF 5 : VF N
6 : IG1 6 : VF2
7:N 7 : ST R
Ra
8 : IG2 8 : Ra
9 : VR
VF : Forward solenoid
VR : Reverse solenoid
ST : Starting motor relay
Ra : Backup lamp & buzzer
2-35

OIL PRESSURE MEASUREMENT AND


STALL TEST
1. Maintain the vehicle horizontally and warm up the engine
with the direction switch at the N position.
2. Measure the oil level.
(1) Measure the oil level during idling using the level gauge.
(2) If the oil level is not between F (upper limit) and L (lower
limit), adjust to an appropriate level.

3. Measure the oil pressure.


Main pressure
Outlet (1) Check and adjust the engine speed. (See page 1-11.)
pressure (2) Stop the engine and jack up at the front axle to float
wheels (both tires). 3
(3) Set the oil pressure gauge. (If three oil pressure
gauges are available, measure the main, clutch and
torque converter outlet pressures at a time.)
Clutch Use the adapter (SST) at each of the main pressure
pressure and clutch pressure detection port.
SST 09350-23320-71
(SST thread size: Valve side 5/16 UNF, Oil pressure
gauge side PT1/8)
(4) Start the engine, set the direction switch to the N posi-
tion, and measure the main pressures at idling and
2000 rpm, and the torque converter outlet pressure at
2000 rpm.
(5) Operate the direction switch to each shift position and
measure clutch operating pressures at idling and 2000
rpm.

Note:
Do not step on the inching pedal during measurements
of oil pressures.

Standard kPa (kgf/cm2) [psi]


Detecting pressure Plug size Idling 2000 rpm
Main pressure PT 1/8 (SST) 735 ~ 1324 (7.5 ~ 13.5) [107 ~ 192] 834 ~ 1373 (8.5 ~ 14.0) [121 ~ 199]
Clutch pressure ↑ ↑ 834 ~ 1324 (8.5 ~ 13.5) [121 ~ 192]
Torque converter outlet
pressure
PT 1/8 − 49 ~ 441 (0.5 ~ 4.5) [7 ~ 64]
2-36

4. Carry out the stall test.


(1) Load a cargo having near the permissible maximum
load, firmly locate stoppers to the front and rear wheels,
and activate the parking brake.

Caution:
Prevent the vehicle from movement by pulling at
the rear by a wire as shown, for safety during test.

(2) Warm up the engine and measure the idling speed,


no-load static maximum revolution and relief down.
(See page 1-11.)
(3) Set the direction switch to the forward position, press
on the acceleration pedal all the way and measure the
stall revolution after the revolution is stabilized.
Accelerator pedal
Standard:
4Y: Approx. 2100 rpm
1DZ-II: Approx. 2100 rpm
2Z: Approx. 2050 rpm

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