Torque Converter Transmission
Torque Converter Transmission
GENERAL
F R
F: Forward
R: Reverse
2-3
2
D D
C C
B B
A A
A-A: Accumulator
C C
B B
A A
Safety
valve
Regulator valve
In-line strainer
Relief
Shift change valve
valve (R)
Oil pump
Cooler
2
2-6
SPECIFICATIONS
Maker Aisin
Torque converter
392 (4.0) [57]
outlet pressure kPa(kgf/cm2)[psi]
Torque converter
9.0 (2.38)
oil capacity (USgal)
4Y•1DZ-II 4Y•1DZ-II 2Z
COMPONENTS
Torque Converter Housing
3201
3201-166
Torque Converter
3202
2-8
3203
2-9
3204
3
2-10
Control Valve
3206
2-11
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
No starting at R
Start at N range
At F
Inching
start
At R
Slippage At F
At R
No inching operation
Abnormal noise
2-13
3
2-14
*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.
Installation Procedure
The installation procedure is reverse of the removal procedure.
2-15
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.
6 Remove the accumulator valve, inching valve and regulator valve. [Point 2]
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.
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.
[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.
T = 9.81 ~ 18.6
(100 ~ 190)
[7.24 ~ 13.7]
3
4
Removal Procedure
1 Drain the torque converter oil.
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.
Inspection:
Measure clearance between the oil pump driven gear and
crescent.
Inspection:
Measure clearance between the oil pump drive gear and
crescent.
Inspection:
Measure clearance between the pump body and each gear.
Inspection:
Measure clearance between the oil pump drive gear bush-
ing and stator shaft.
[Point 4]
Installation:
SST SST 09950-60020 ---
09950-70010 ---
SST
2-21
Removal Procedure
1 Remove the engine hood. (See page 9-5.)
5 Diesel Vehicle:
Remove the sedimenter bracket set bolt to make the bracket free.
7 Remove fuse box and electrical parts plate set bolts to set them free.
14 Remove the oil pump set bolts to set the pump free.
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
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.
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]
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.)
10 Remove the bearing spacer from the output gear portion. [Point 7]
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.
[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.
[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
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 ---
[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.
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
F
R
2-31
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]
Reassembly Procedure
The reassembly procedure is reverse of the disassembly procedure.
2-32
[Point 1]
Inspection:
Measure the clutch disc thickness.
Inspection:
Measure thickness of the clutch plate.
Inspection:
Measure height of the camber plate curving.
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.
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)
[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.
[Point 3]
Disassembly:
Pinch the rib of clutch piston by pliers with cloth in-between
and remove the piston.
2-34
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
Note:
Do not step on the inching pedal during measurements
of oil pressures.
Caution:
Prevent the vehicle from movement by pulling at
the rear by a wire as shown, for safety during test.