U140

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TOYOTA/LEXUS U 140E/ F, U 240E

INDEX TRA NSM I SS SSII ON APPL I CATI ON BY VE H I CL E................ E........................... ..................... ..................... ..................... .................... ..................... ..................... ..................... ............. 3 I DE NTI F I CATI ON CODE ST STAM AM PI NG L OCATI ON...... ON.......... ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ...... 4 COM PONE NT A PPL I CATI ON CH ART........... ART..................... ..................... ..................... .................... ..................... ..................... ..................... ..................... .................... ..................... ........... 5 CONN ECT OR AN D I NT ERN AL HA RNE SS SCHE M ATI C.......... C..................... ..................... ..................... ..................... .................... ..................... ..................... ............ 6 WI RI NG DI AGRA M AN D CONN ECT ORS... ORS............. ..................... ..................... .................... ..................... ..................... ..................... ..................... .................... ..................... .............. ... 8 TRA NSM I SS SSII ON RAN GE SENSOR........... SENSOR..................... ..................... ..................... ..................... ..................... .................... ..................... ..................... ..................... ..................... ................ ...... 10 TU RBI NE AN D OUT PUT SPEED SENSORS.... SENSORS............... ..................... .................... ..................... ..................... ..................... ..................... .................... ..................... ................... ........ 12 VE H I CL E SPEED SENSOR............ SENSOR...................... ..................... ..................... .................... ..................... ..................... ..................... ..................... .................... ..................... ..................... .................. ........ 13 DT C DE SCRI PTI ONS.......... ONS.................... ..................... ..................... ..................... ..................... .................... ..................... ..................... ..................... ..................... .................... ..................... .................... ......... 14 TRA NSAX L E DI SASS SASSEM EM BL Y. Y............ ..................... .................... ..................... ..................... ..................... ..................... .................... ..................... ..................... ..................... ..................... .............. .... 15 COM CO M PO PONENT NENT REBUI LD SECTI SECTI ON: TORQU E CONV ERT ER H OUSI NG................. NG........................... ..................... ..................... .................... ..................... ..................... ..................... ..................... .................... ............ .. 35 UN DE RDRI VE PL AN ETA RY ASSEM BL Y.......... ..................... ..................... ..................... ..................... .................... ..................... ..................... ..................... .................. ....... 39 DI F F ERE NT I AL ASSEM BL Y. Y............ ..................... ..................... ..................... .................... ..................... ..................... ..................... ..................... .................... ..................... ................ ..... 45 OI L PUM P ASSEM BL Y........... ..................... .................... ..................... ..................... ..................... ..................... .................... ..................... ..................... ..................... ..................... ................. ....... 48 DI RECT (C2) CL UT CH ........... ..................... ..................... ..................... .................... ..................... ..................... ..................... ..................... .................... ..................... ..................... ................. ....... 52 F ORWARD (C1) CL UT CH .......... .................... .................... ..................... ..................... ..................... ..................... .................... ..................... ..................... ..................... ..................... ............. ... 55 UN DE RDRI VE (C3) CL UT CH ........... ..................... .................... ..................... ..................... ..................... ..................... .................... ..................... ..................... ..................... ................. ...... 59 2ND BRA KE (B 1).......... 1)..................... ..................... .................... ..................... ..................... ..................... ..................... .................... ..................... ..................... ..................... ..................... ................. ....... 62 NO. 1 ONE WA WAY Y CLU TCH (F 1) F REEW H EE L OPERATI ON...... ON.......... ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ...... 67 NO. 2 ONE WA WAY Y CLU TCH (F 2) F REEW H EE L OPERATI ON...... ON.......... ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ...... 68 VAL VE BOD Y ASSEM BL Y........... ..................... .................... ..................... ..................... ..................... ..................... .................... ..................... ..................... ..................... ..................... ............ .. 69 UPPE R VAL VE BOD Y CH ECK BA L L L OCATI ONS.......... ONS..................... ..................... .................... ..................... ..................... ..................... ..................... .............. .... 71 L OWE R VAL VE BOD Y CH ECK BA L L L OCATI ONS........... ONS..................... ..................... ..................... ..................... ..................... .................... ..................... ............. 72 SOLE NOI D OPERAT I ON AN D CH ECK PROCED URE .......... .................... .................... ..................... ..................... ..................... ..................... ................. ....... 75 VAL VE BOD Y RE-A SS SSEM EM BL Y PROCED URE ........... ..................... ..................... ..................... .................... ..................... ..................... ..................... ..................... .......... 78 TRA NSM I SS SSII ON F I NA L ASSEM BL Y. Y........... ..................... ..................... ..................... ..................... .................... ..................... ..................... ..................... ..................... ..................... ............. 82 TORQU E SPECI F I CATI ONS........... ONS...................... ..................... ..................... ..................... ..................... ..................... .................... ..................... ..................... ..................... ..................... ............... ..... 113 CASE PASS ASSAGE AGE I DE NTI F I CATI ON F OR AI R TESTI NG..... NG......... ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ .... 114 L I NE PRESSURE PRESSURE TE STI NG, TAP TAP L OCATI ONS, F L UI D CHE CKI NG PROCED PROCED URE....... URE........... ........ ........ ........ ........ ........ ........ ........ ...... 115 ECM M EM ORY RESET PROCED URE ........... ..................... .................... ..................... ..................... ..................... ..................... ..................... ..................... .................... ..................... ............. 116 SPECI AL SERVI CE TOOL S (SS (SST).................. T)............................. ..................... ..................... ..................... .................... ..................... ..................... ..................... ..................... .................... ............ ..117

AUTOMATIC TRANSMISSION TRANSMISSION SERVICE SERVICE GROUP 18635 S.W. 107TH. AVE. CUT LE R BAY BAY, FL 33157 (305) 670-4161 Copyr ight © ATSG 2009

INTRODUCTION

Published F ebruar y, 2009 2009

TOYOT TOY OTA/L A/L EX US U14 U140E/F AN D U24 U240 0E SERI ES Starting at the beginning of production for the 1998 model year for Lexus Lexu s and 2000 for Toyota, a new transaxle, designated as the, U140/U240 series was introduced into service. This Transaxle’s Transaxle’s shift points, and shift feel are electronically controlled by a Powertrain Control Module. This is accomplished b y the PCM monitoring engine load and adjusting solenoid duty cycle to match pressure rise and shift feel. The PCM also monitors the turbine and output speed sensors to calculate calcu late gear ratio and the Transmission Range Sensor for gear selection.This front wheel drive transaxle has four forward gears, gea rs, and one reverse gear. The unit is comprised of three conn ecting clutches, three holding brakes, three planetary gear sets, and two one-way clutches. In addition, there is a clutch located in the torque converter which is applied via the ECM for increased fuel economy. The primary difference between the U140E/F and the U240E is clutch capacity. The U140 series being used primarily in the V6 applications, thus, containing a greater number of friction elements in the individual clutch packs, while the U240 series is utilized primarily in the smaller 4 cylinder engines. We wish to than k Toyota Toyota M otor Company for the inf ormation and some some il lustrations lustrations.. We also wish wish to than k G-COR A utomoti ve Corp. for providi ng the transmiss transmission s that made thi s bookl bookl et possi possi ble. No part of any ATSG publication may be reproduced, stored in any retrieval system or transmitted in any form or by any means, including but not limited to electronic, mechanical, photocopying, recording or otherwise, without written permission of Automatic Transmission permission Transmission Service Group. This includes all text illustrations, tables and charts. Th e in for mation and part n umbers contain ed in th is booklet booklet have have bee be en carefu ll y compil compil ed fr om in dus dustr tr y sour sour ce cess known for their r eli abil ity, but AT SG does does not guar antee its accur accur acy acy.. Copyrr igh t © ATSG 2009 Copy 2009 PETER LUBAN

WAYNE COL C OL ONNA

DALE ENGLAND

TEC HNICAL CONSUL CONSULTAN TANT T

TEC HNIC AL CONSULTANT CONSULTANT


GERALD CAMPBELL

JIM DIA DIAL L

TECHNICAL SU SUPERVISOR PERVISOR


GABE DE LOS REYES

ED KRUSE



RO LAND ALVARE ALVAREZ Z

GREGORY LIPNICK

TEC HNICAL CONSULT CONSULTANT ANT


JON GLATSTEIN

DAVID DA VID C HALK ER


TEC HNICAL C ONSUL ONSULTAN TANT T

RICHARD GRAHAM

GREG CATANZARO


TEC HNICAL C ONSUL ONSULTA TANT NT

AUTOMATIC TRANSMISSION SERVICE GROUP 18635 S.W. 107T H. AVE. AVE. CUT LE R BAY BAY, FL 33157 (305) 670-4161

Technica echnicall Service Information Informa tion Toyota/L exu s U 140/U240 Tr ans ansmi misssi on App A ppll i ca cati tion on by Ve Vehi cle

MAKE

MODEL

YE AR

ENGINE

LEXUS

ES 300

1999 - 2001

V6 3.0L

U140E

L E XUS

R X 300

1998 - 2003

V6 3.0L

U140E

LEXUS

RX 300

1998 - 2003

V6 3.0L 4X4

U140F

T O YO TA

C AM R Y

2002 - 2004

L4 2.0L

U240E

T O YO TA

C AM R Y

2002 - 2003

V6 3.0L

U140E

T O YO TA

CELICA GTS

2000 - 2005

L4 1.8L

U240E

T O YO TA

H I G H L ANDE R

2001 - 2003

L4 2.4L - V6 3.0L 4X4

U140F

T O YO TA

H I G H L ANDE R

2001 - 2003

V6 3.0L

U140E

T O YO TA

H I G H L ANDE R

2004 - 2007

L4 2.4L

U240E

T O YO TA

H I G H L ANDE R

2004 - 2007

L4 2.4L - V6 3.0L 4X4

U140F

T O YO TA

M AT R I X

2003 - 2006

L4 1.8L

U240E

T O YO TA

R AV4

2000 - 2007

L4 2.0L/2.4L 2.0L /2.4L 4X4

U140F

T O YO TA

R AV4

2000 - 2007

L4 2.0L/2.4L

U241E

T R ANSM I SSI O N

T O YO TA

SC I O N t c

2004 - 2007

L4 2.4L

U241E

T O YO TA

S O L AR A

2002 - 2005

L4 2.4L

U241E

Copyr ight © 2009 ATSG

Figure 1

3

Technica echnicall Service Information Informa tion I DENTI FI CA CATION TION CODE ST STAM PING LOCATION LOCATION

I de denti nti fi cation code is cas castt i nto t he case case overr the U nderdr ive Se ove Section.


Figure 2

4

AUTOMATIC AUTOMA TIC TRANSMISSION SERVICE GRO UP

Technica echnicall Service Information Informa tion TOYOTA/L EX US U140 U140/U240 /U240 COM CO M PO PONENT NENT APPLI APPLI CA CATI TI ON CHA RT 1st. & Rev. Brake (B2)

2nd Brake (B1)

Direct Clutch (C2)

Forward Clutch (C1)

No. 1 One Way Way Clutch (F1)

U/D Brake (B3)

No. 2 One Way Way Clutch (F2) U/D Clutch (C3)

Gear Range

Fwd Clutch C1

Dir Clutch C2

U/D Clutch C3

2nd Brake B1

L/R Brake B2

U/D Brake B3

No. 1 No. 2 One Way One Way Clutch Clutch F1 F2

ON

Park Reverse

ON

ON

ON ON

Neutral D-1st Gear

ON

ON

D-2nd Gear

ON

D-3rd Gear

ON

ON

D-4th Gear

ON

ON

2-1st Gear

ON

2-2nd Gear

ON

1-1st Gear

ON

ON

ON

ON

ON

ON

ON

ON

ON ON ON

ON

ON ON

ON

ON ON

ON

ON


Figure 3


5

Technica echnicall Service Information Informa tion SOLENOID SOLE NOID INTE RNAL HARNESS HARNESS AN AND D CONNECTOR I.D. SOLENOID RESISTANCE VALUES

10 PI PIN N CONNECTOR 1

6

2

7 8

3

9

4 10

5 CONNECTOR I .D .D.. Terminal

Function

Internal wire Color

1

THO (temp +)

Orange

2

SLT +

Orange

3

DSL +

Green

4

SL2 +

Yellow

5 6

SL1 + E2 (temp -)

White Orange

7

SLT -

Green

8

S4 +

Red

9

SL2 -

Brown

10

SL1 -

Black

RESISTANCE VALUES Connect to terminals

Resistance

Temp Sensor

1 and 6

3.8k ohms @ 70°F

SLT

2 and 7

4.5 to 6.0

DSL

3 and Gnd to the case

11 to 15

SL2

4 and 9

4.5 to 6.0

SL1

5 and 10

4.5 to 6.0

S4

8 and Gnd to the case

11 to 15

Test


Figure 4

6


Technical Service Information 10 PIN CONNECTOR INTERNAL HARNESS SCHE MATIC

1

6

2

7 8

3

9

4 10

5 Terminals Orange

1 6

Orange

2 Green

3

Yellow

4

8

DSL

Brown

9

10

SLT

Green

7

5

Temp Sensor

Orange

White Black

SL2

Red

SL1

S4

Note: Th e DSL and S4 Solenoi d are grou nded to the case


Figure 5

AUTOMATIC TRANSMISSION SERVICE GRO UP

7

Technical Service Information TOYOTA U240 WIRING DIAGRAM Example: 2001 RAV4 2.4L HOT AT ALL TIMES

5

3

9 F

3 C

1 1 G

9 G

K L B / T H W

T H W / N R G

D E R / K L B

) U L B T L R O ( T H W / D E R

GROUND A (FRONT OF RIGHT FRONT FENDER)

IGN SW OD LP START SYS EFI RELAY OD SWITCH BRAKE SW BATTERY EOM

BLK/ORG OR(WHT)

5

LT GRN/BLK OR(WHT)

7

BLK/RED OR(WHT)

8

GRN/WHT OR(WHT)

10

LT GRN OR (WHT)

15

GRN/WHT OR(WHT)

16

BLK/RED OR(LT GRN)

22

BRN OR (WHT)

GAUGE FUSE 10A

5 D

2 D

N R B

N R B

2

4 K L B / T H W

N R G T L

” D N I E S R E V E R “

) ) ) ) ) ) T T T T T T H H H H H H W W ( W W W W ( ( ( ( ( R R R R R R O O O O O O N K K T K N L R R L L H B G G / B / B W / T T N U / N L L R L U R L G G B B T T L L

) T H W ( R O K L B / D E R

MAN 2 MAN L OIL WARN NSW VSS METER

SOL S4

GND E04 VC GND E05 GND E1 GND E2

SOL SLT SOL SLT + SOL SL1 + SOL SL2 + SOL SL1 NC + NT NT + ATF TEMP SOL SL2 GND E2 THW VTA NC GND E03 GND E02

” D N I K R A P “

3 G ENGINE ROOM J/B (LEFT SIDE OF ENGINE 5 COMP’T) D

BRN

J/C 5 (BEHIND CENTER OF DASH)

RED/BLU

3

A

BLU/RED

1

B

B

RED/BLK

2

D

BLU/WHT

5

BLU/BLK

7

J/C 8

2

RED/BLK OR (WHT)

3

LT GRN/BLK OR (WHT)

BLU/WHT OR (WHT)

F

12

LT GRN OR (WHT)

BLU/WHT OR (WHT)

A

16

PINK OR (WHT)

BLU/BLK OR (WHT)

A

C

20

BLK/YEL OR (WHT)

LT GRN/BLK OR (WHT) E

E

22

VIO/WHT OR (WHT)

6

RED/WHT

12

YELLOW

PASSENGER SIDE J/B (BEHIND LEFT SIDE OF DASH”) 9 C

LT GRN OR (WHT)

D

LT GRN OR (WHT)

D

N

WHT/BLK

2

YELLOW

8

WHT/BLK

17

BROWN

18

BROWN

YEL/GRN

6

YEL/RED

7

GRN/WHT

8

PINK

9

VIOLET

14

RED

15

BLACK

16

WHITE

17

GREY

20

YEL/BLK

21

WHT/BLK

22

WHITE

24

BLU/RED

26

GREEN

30

WHT/BLK

31

WHT/BLK

CONN E4

LT GRN

8

P BLK/YELLOW

FROM STARTER RELAY

9

N

WHT/BLK 6 A/T RANGE SENSOR (LEFT FRONT OF ENGINE COMPARTMENT ATTACHED TO TRANSAXLE)

G100

12 (ENGINE HARNESS RIGHT SIDE OF DASH)

BLACK

1

WHITE

2

“NT” TURBINE SPEED SENSOR ATTACHED TO TRANSAXLE

RED

2

GREEN

1

W O L L E Y

“NC” COUNTER GEAR SPEED SENSOR ATTACHED TO TRANSAXLE

7 C N N R R B B A

ENGINE CONTROL UNIT (ECU) (BEHIND RIGHT SIDE OF DASH) A

A

J/C 6 (BEHIND RIGHT SIDE OF DASH)

D E R / U L B 3

W N O W L L O E R Y B 1

2

K L B / L E Y

K N I P

T E L O I V

T H W / N R G

T H W / D E R 3

1

N R G

G R O

E T I H W

N W O R B

9

4

0 1

5

2

1

N R B

L E Y

K L B

T H W

K K K K K L L L L L N B / B / B / B / B / W T T T T T O H H H H H R W W W W W B

EC (LEFT REAR OF CYLINDER HEAD)

2 L

F

(RIGHT KICK PANEL)

CONN E5

5

D

LT GRN/BLK 4

WHT/BLK

1

2 L S

EB (LEFT REAR OF CYLINDER BLOCK)

THROTTLE POSITION SENSOR (TOP RIGHT REAR OF ENGINE)

P

R


2 P

CONN E6

GRN/WHT OR (WHT)

C

J/C 7

BLU/BLK OR (WHT)

INSTRUMENT CLUSTER SYSTEM

5 H

DRIVER SIDE J/B (BEHIND LEFT SIDE OF DASH)

(BEHIND RIGHT SIDE OF DASH)

1

WHT/BLK

6 H

1

) ) T T H H W ( W ( R R O O K K L L B / B / D D E E R R

3

1 GRN/WHT

GRN/WHT (OR PNK)

RED/BLU

3 5 5 8

STOP LIGHT SWITCH (BEHIND LEFT SIDE OF DASH)

RED/BLU

) T H W ( R O D E R / U L B


CONN E8

CONN E7

SOL DSL

6 D PASSENGER SIDE J/B (BEHIND LEFT SIDE OF DASH) 5 B

2 STARTING SYSTEM

2 7

REVERSE

RED/WHT (OR PNK) 2

” ” D P I M ” ” ” N E D D D ” T N N N L A F L I I I R F I L 2 E T O O N N I V U T A A R E D / / N O A “ M “ M “ D “ “ “

WHT/BLK DRIVE

3 H

RED/BLU

OVERDRIVE SWITCH


STOP FUSE 10A

9 J

2 H BLK/ORG (OR WHT)

RED/WHT (OR LT BLU)

2

HOT AT ALL TIMES

ENGINE CONTROLS

SHORT PIN 1 2

2

HOT IN ON OR START

IG 2 FUSE 10A

EFI 2 FUSE 5A

1

1

ENGINE ROOM J/B (LEFT SIDE OF ENGINE COMPT)

EFI 1 FUSE 20A

EFI MAIN RELAY

BATTERY

HOT IN ON OR START

ENGINE COOLANT TEMPERATURE SENSOR (ON REAR OF ENGINE)

1 L S

Y E R G

L S D

D E R / L E Y

N R G / L E Y

5 C L E Y

6

2

7

8

G R O

G R O

N R G

D E R

N W O R B

T O T

T L S

4 S

4 F

ENGINE ROOM J/B (LEFT SIDE OF ENGINE COMPARTMENT)

W O L L E Y 6 L T A C N E G I S CRUISE CONTROL ECU (BEHIND LEFT END OF DASH)

AUTOMATIC TRANSAXLE SOLENOIDASSEMBLY


Figure 6

8

AUTOMATIC TRANSMISSION SERVICE GR OUP

Technical Service Information ENGINE/TRANSMISSION CONTROLS CONNECTOR VIEW S Example: 2001 RAV4 2.4L

12 34 OVERDRIVE SWITCH

3

4

5

6

7

9 10 11 12 1 3 1 4 1 5 1 6

8 5

A/T RANGE SENSOR

CONNECTOR E4

2

1 2 3 4 5 6 7 8

2 3 4 9 6 1

1

CONNECTOR C20

CONNECTOR P1 GREY

CONNECTOR O2 BLUE

CONNECTOR E5

7

8

9

1

2

3

4

5

CONNECTOR E6

6

7

1 2 3 4 5 6

10 11 12 13 14 15 16 17 18 19 20 21

8 9 10 11 12 13 14 15 16

22 23 24 25 26

17 1 8 1 9 20 21

27 28

29 30 31

22 23 24

7 8 9 10 11 12 13 14 15

16 17

CRUISE CONTROL ECU

CONNECTOR E7

CONNECTOR E8

1 2 3 4 5 6

7 8 9

1 2 3 4 5

6 7

10 11 12 13 14 15 16 17 18 19

8 9 10 11 12 13 14 15

20 21 22

16 17

23 2 4 25 26 27 28

18 19 20 21 22

ENGINE CONTROL MODULE (ECM)

CONNECTOR E2 GREEN

1 2

CONNECTOR T1 BLACK

1

2

CONNECTOR S8 BROWN

1

3

2

3 ENGINE COOLANT TEMPERATURE SENSOR (ECT)

CONNECTOR C3 BLACK

1

2

N/C COUNTER GEAR SPEED SENSOR

THROTTLE POSITION SENSOR

A/T BRAKE SWITCH

CONNECTOR T2 BLACK

1

CONNECTOR V1 BLACK

2

N/T TURBINE SHAFT SPEED SENSOR

4

1

2

3

VEHICLE SPEED SENSOR (COMBINATION METER)


Figure 7


9

Technical Service Information CHECKING PARK/NEUTRAL SWITCH TRANSMISSION RANGE SENSOR CONNECTOR VIE W 6

1

7

2

4

9

84540-48010 AV2312

N A i S

En sur e the tab and the li ne on the switch are ali gned in Neutral

3

5

8

H 3 2 7 0 4 0

1 4

CONNECTOR VIE W 6

1

2

3

NOTE: PIN CONFIGURATION MAY APPEAR INCORRECT, HOWEVER, IT AGREES WITH AVAILABLE WIRING DIAGRAMS. CONTINUITY TEST CHART WAS TAKEN FROM AN ACTUAL P/N SWITCH.

5

8

7

4

9

Di sconnect the Park /Neutr al switch connector and check for conti nu ity between the termin als li sted i n the chart below

RANGE POSITION

TERMINALS

P

3&1

R

3&2

N

3&5

D

3&7

2

3&4

L

3&8

9&6 9&6

Note: T here shoul d be contin ui ty only on the terminal s li sted above Copyr ight © 2009 ATSG

Figure 8

10


Technical Service Information TOYOTA U240 WIRING DIAGRAM Example: 2001 RAV4 2.4L HOT IN ON OR START

ENGINE CONTROL MODULE (ECM) VOLTAGE CHECK S FOR TRANS RANGE SENSOR

9 J

RED/BLU

RANGE TERMINALS VOLTAGE R

2 & ground

9-14

D

7 & ground

9-14

2

4 & ground

9-14

L

8 & ground

9-14

PASSENGER SIDE J/B (BEHIND LEFT SIDE OF DASH)

3 G ENGINE ROOM J/B (LEFT SIDE OF ENGINE 5 COMP’T) D

CONN E7

MANUAL 2

REVERSE

12

LT GRN OR (WHT)

3

LT GRN/BLK OR (WHT)

2

5 B RED/BLU

Note: Voltage should only be present on the terminals listed above all other terminals related to the TRS must be 0 Volts

MANUAL LOW


GAUGE FUSE 10A

RED/BLU

3

BLU/RED

1

RED/BLK

2

BLU/WHT

5

P

R N D

7

RED/BLK OR (WHT)

2

4

L DRIVE

1

JUNCTION CONNECTOR (BEHIND RIGHT SIDE OF DASH)

BLU/BLK OR (WHT)

J/C 7

ENGINE CONTROL UNIT (ECU) (BEHIND RIGHT SIDE OF DASH)

8

J/C 8

P 9

LT GRN OR (WHT)

N

6 D LT GRN OR (WHT)

LT GRN OR (WHT) D

F

A/T RANGE SENSOR (LEFT FRONT OF ENGINE COMPARTMENT ATTACHED TO TRANSAXLE

LT GRN/BLK OR (WHT) E LT GRN/BLK OR (WHT)


E

BLU/BLK OR (WHT) A BLU/BLK OR (WHT)

BLU/BLK OR (WHT) A

A

BLU/WHT OR (WHT) F

D

B

B

C

A

RED/BLK OR (WHT) BLU/RED OR (WHT)

WHT/BLK BLU/WHT OR (WHT)

RED/BLK OR (WHT) G100 BLU/RED OR (WHT)

(FRONT OF LEFT FRONT FENDER)

RED/BLK OR (WHT) STARTER

RED/BLK OR (WHT)


RED/BLK OR (WHT)

1

3

1

2 J/C 4 (BEHIND CENTER OF DASH)

2 2 7 4 WHITE WHT/BLK 5 1

3 1 C

8 1

9 1

0 2

8

0 1

9

4 1 C

S3

BLK/YELLOW

BLK/WHT

ENGINE ROOM RELAY BOX (ON LEFT FRONT STRUT TOWER)

3

2

5 STARTER RELAY 1

G203 (RIGHT KICK PANEL)

BLACK L

2

D

N

R

BLACK

P

12 VOLTS IN START

C3 FROM IGNITION SWITCH

G4

12 VOLTS IN START

DRIVER SIDE JUNCTION BOX (BEHIND LEFT SIDE OF DASH)

INSTRUMENT CLUSTER


Figure 9


11

Technical Service Information TOYOTA U240 NT AND NC SENSOR CHE CK

(NT) TURBINE SPEED SENSOR

(NC) COUNTER GEAR SPEED SENSOR

2

1

2

1

NC Coun ter Gear Speed Sensor (sensor connector vi ew)

NT Tur bin e Speed Sensor (sensor connector vi ew)

Conn ect ohm m eter between the ter minal s 1& 2 on each sensor, the value should be 620 +/- 60 Ω NT & NC P ar tia l wire Schema tic

D E R 2

N E E R G 1

COUNTER GEAR SPEED SENSOR

K C A L B 1

14 26

BLACK

15

WHITE

16

NC+ NCNTNT+

ENGINE CONTROL MODULE (ECM) (BEHIND RIGHT SIDE OF DASH)

E T I H W 2

TURBINE SPEED SENSOR


Figure 10

12

RED GREEN


Technical Service Information TOYOTA U240 VEHICLE SPEED SENSOR CHEC K

INSTRUMENT CLUSTER CONNECT OR A C12 (VSS)

Rear Vi ew of Case

1 2 3 4 5 6 7 8 9 10 11121314151617181920

VSS SENSOR CONNECTOR FACE VIEW

3

2 1 Termi nal I .D. 1 Ignition voltage (from Fuse) 2 Ground 3 Signal out Vehi cle speed is sent t o the Combin ation M eter th en to th e ECM . The VSS generates a F our Pul se per output r otation signal t hat i s conditi oned and conver ted to a digi tal signal by the Combinati on M eter.

SPD

12

VEHICL E SPEE D SENSOR PARTIAL WIRING SCHEMATIC

VIO/WHT


CRUISE CONTROL ECU (BEHIND LEFT SIDE OF DASH)

22

6 E

6 2 J

6 M

9 J RED/BLU OR (LT BLU

T H W VIO/WHT

VIO/WHT


GUAGE FUSE 10A

VIO/WHT

SPD

12V. IN ON OR START

C13 CONN B

CONN E7

WHT B1

R SPEEDO E O T R U C P I M M O C

ENGINE CONTROL MODULE (ECM) (BEHIND RIGHT SIDE DASH) WHT A4

WHT A6 SI

SE

IG+

3

BLU/BLK

WHT

2

RE D/ YEL

WHT

1

RE D/ BLU

VEHICLE SPEED SENSOR (INST. CLUSTER) (ON TRANSAXLE NEAR REAR OF ENGINE)

C12 CONN A COMBINATION METER

U L B / D E R 9 D

COMBINATION METER (CONNECTOR VIEW REAR)

U L B / D E R 0 1 G


U L B / D E R

U L B T L ( R O U L B / D E R

6 Q

5 B

IGN

1 1 1 2 1 3 1 4 1 5 1 6 1 7 1 8 1 9 2 0

1 2

3 4

5 6 7

8 9 1 0

C15 CONN D

1 1 1 2 1 3 1 4 1 5 1 6 1 7 1 8 1 9 2 0

1 2

3 4

5 6 7

8 9 1 0

C14 CONN C

1 1 1 2 1 3 1 4 1 5 1 6 1 7 1 8 1 9 2 0

1 2

3 4

5 6 7

8 9 1 0

C13 CONN B

1 1 1 2 1 3 1 4 1 5 1 6 1 7 1 8 1 9 2 0

1 2

3 4

5 6 7

8 9 1 0

C12 CONN A

ENGINE ROOM J/B (LEFT SIDE OF ENGINE COMPARTMENT


Figure 11


13

Technical Service Information TOYOTA/LEXUS U140/U240 Diagnostic Troub le Code Descr iptions

Code

Description

* P0130

Heated Oxygen Sensor Circuit Malfunction (Bank 1 Sensor 1)(Except Calif.)

* P0133

Oxygen Sensor Circuit Slow Response (Bank 1 Sensor 1)

* P0135

Heated Oxygen Sensor Heater Circuit Malfunction (Bank 1 Sensor 1)

* P0136

Oxygen Sensor Heater Circuit Malfunction (Bank 1 Sensor 2)

* P0141

Heated Oxygen Sensor Heater Circuit Malfunction (Bank 1 Sensor 2)

* P0325

Knock Sensor 1 Circuit Malfunction

* P0330

Knock Sensor 1 Circuit Malfunction (LEXUS MODELS)

P0500

Vehicle Speed Sensor Malfunction

P0710

Transmission Fluid Temperature (TFT) Sensor Circuit Malfunction

P0750

Shift Solenoid A (Solenoid Valve SL1) Malfunction (Performance)

P0753

Shift Solenoid A (Solenoid Valve SL1) Circuit Malfunction (Electrical)

P0755

Shift Solenoid B (Solenoid Valve SL2) Malfunction (Performance)

P0758

Shift Solenoid B (Solenoid Valve SL2) Circuit Malfunction (Electrical)

P0765

Shift Solenoid D (Solenoid Valve S4) Malfunction (Performance)

P0768

Shift Solenoid D (Solenoid Valve S4) Circuit Malfunction (Electrical)

P0770

Shift Solenoid E (Solenoid Valve DSL/TCC) Malfunction (Performance)

P0773

Shift Solenoid E (Solenoid Valve DSL/TCC) Circuit Malfunction (Electrical)

P1520

Stop Light (Brake ON/OFF) Switch Circuit Malfunction

P1725

NT Revolution Sensor Circuit (Turbine Speed Sensor)

P1730

NC Revolution Sensor Circuit (Counter Gear Speed Sensor)

P1760

Linear Solenoid Pressure Control (Solenoid Valve SLT) Circuit Malfunction (Electrical)

P1780

Park/Neutral Position Switch Malfunction

* Engine related codes that can result in no “Commanded” up-shift to 4th gear. Copyr ight © 2009 ATSG

Figure 12

14


Technical Service Information SAFETYPRECAUTIONS

TRANSAXLEDISASSEMBLY

Service in for mation provided in thi s manual by ATSG is in tended for use by prof essional quali fi ed techni cians. Attemptin g repair s or service with out th e appropri ate tr ain in g, tools and equi pment coul d cause in ju ry to you or to others. Th e service procedur es we recommend and describe in thi s manu al ar e eff ective methods of performi ng service and repair on thi s tr ansmission. Some of th e procedur es requi r e the use of special tools that ar e designed for specific purposes. Thi s manual contains CAU TI ONS that you must obser ve careful ly i n order t o r educe the r isk of in ju r y to yourself or to others. Thi s manu al al so contai ns NOTE S that must be careful ly f ollowed in order to avoid impr oper service that may damage the vehi cle, tools and/or equipment.

Ex ter nal components 1. The transaxle should be cleaned on the outside to remove dirt or grease prior to disassembly. 2. This transaxle can be disassembled quite easily on a suitable workbench without the aid of any holding fixture for rotation. 3. Remove the torque converter from transaxle as shown in Figure 13. Cauti on: Th e tor que converter i s heavy, use caution wh en r emoving to avoid personal i nj ur y or damage to torqu e conver ter.

Continued on Page 16


Figure 13


15

Technical Service Information TRANSAXLEDISASSEMBLY External components contin ued 4. Remove the retaining nut, lock washer and control shaft lever as shown in Figure 14. 5. Use a screwdriver to pry up tabs on locking washer, then remove the retaining nut and locking washer as shown in Figure 14. 6. Remove the two retaining bolts from the park/neutral position switch then gently pry and remove the switch away from the transmission as shown in Figure 14. 7. Remove the (NT) turbine shaft speed sensor retaining bolt and the turbine shaft speed sensor as shown in Figure 14. 8. Remove and discard the o-ring.

9.Remove the (NC) counter gear speed sensor retaining bolt and the counter gear speed sensor as shown in Figure 14. 10.Remove and discard the o-ring. 11.Remove the (VSS) vehicle speed sensor retaining bolt and the vehicle speed sensor as shown in Figure 14. 12.Remove and discard the o-ring. 13.Remove the solenoid internal harness connector retaining bolt as shown in Figure 14. Note: Only r emove the retain in g bolt, D O N OT attempt to r emove the case conn ector at th is tim e. Damage to in ter nal har ness wir es wil l result. Continued on Page 17 RETAINING BOLT

RETAINING BOLT (NT) TURBINE SPEED SENSOR O-RING

(VSS) VEHICLE SPEED SENSOR

RETAINING BOLT (NC) COUNTER GEAR SPEED SENSOR

O-RING O-RING SOLENOID INTERNAL HARNESS CONNECTOR RETAINING BOLT

CONTROL SHAFT LEVER

RETAINING BOLT

RETAINING NUT

RETAINING RETAINING LOCKING NUT AND BOLT WASHER LOCK WASHER

PARK/NEUTRAL POSITION SWITCH (TRANSMISSION RANGE SENSOR)


Figure 14

16


Technical Service Information TRANSAXLEDISASSEMBLY I ntern al components

OIL PAN

1. Remove the eighteen pan bolts from the transmission as shown in Figure 15. 2. Remove the oil pan and oil pan gasket as shown in Figure 15. 3. Remove the oil pan gasket from the pan and discard. 4. Remove the three filter attaching bolts as shown in Figure 16. 5. Remove the oil filter and oil filter gasket as shown in Figure 16. 6. Discard both the oil filter and oil filter gasket. Continued on Page 18

OIL FILTER

OIL PAN GASKET

FILTER BOLT (3 REQUIRED)

PAN BOLT (18 REQUIRED)

FILTER GASKET


Figure 15


Figure 16


17

Technical Service Information

TRANSAXLEDISASSEMBLY I ntern al components contin ued 7. Remove the ATF temperature sensor hold down bolt and bracket as shown in Figure 17. 8. Disconnect the connectors from the solenoids and remove the ATF temperature sensor from the valvebody as shown in Figure 17. 9. Remove the connectors and drape the internal wire harness up and over the pan rail.

Note: I ntern al wi re har ness and connector color s have been pr ovided, however, the connector an d wir e colors in your tr ansmission may be dif fer ent. Shoul d the colors be dif ferent, take the time to carefu ll y label the wir es and connectors to avoid cr oss-connectin g dur in g th e assembl y pr ocess.


SHIFT SOLENOID VALVE S4 “SOLENOID D” (BLACK CONNECTOR SINGLE RED WIRE) ATF TEMPERATURE SENSOR HOLD DOWN BOLT AND BRACKET

SHIFT SOLENOID VALVE SL2 “SOLENOID B” (CLEAR CONNECTOR BROWN AND YELLOW WIRES)

SHIFT SOLENOID VALVE DSL “LOCKUP SOLENOID” (REDDISH BROWN CONNECTOR SINGLE GREEN WIRE)

ATF TEMPERATURE SENSOR (TWO ORANGE WIRES)

SHIFT SOLENOID VALVE SL1 “SHIFT SOLENOID A” (CLEAR CONNECTOR BLACK AND WHITE WIRES)

SOLENOID VALVE SLT “LINE PRESSURE SOLENOID” (CLEAR CONNECTOR GREEN AND ORANGE WIRES)


Figure 17

18


Technical Service Information TRANSAXLEDISASSEMBLY

INTERNAL HARNESS CASE CONNECTOR

I ntern al components contin ued

O-RING

10.Using a twisting motion, turn and remove the internal harness case connector and internal wire harness from the transmission case as shown in Figure 18. Be careful not to damage the wires in the harness. 11. Remove and discard the internal wiring harness o-ring and the o-ring for the ATF temperature sensor. 12.Remove the seventeen valve body to case attaching bolts from the valve body as shown in Figure 19. 13.Remove the valve body assembly from the case by lifting straight up and set aside for the component rebuild section.

O-RING


Note: Valvebody to case attachi ng bol ts are dif fer ent l engths. Refer to char t below f or proper in stall ation in transaxle assembly

Figure 18


BOLT LENGTH

BOLT A: 25 mm (0.984” in.) BOLT B: 41 mm (1.614” in.) BOLT C: 45 mm (1.771” in.) INDICATES LOCATING BOLT

*

A

C

* B A C

C

* B

B


Figure 19


19

Technical Service Information TRANSAXLEDISASSEMBLY(CONT’D) 14.Remove the C1, C3 and B3 accumulator pistons and springs as shown in Figure 20. Note: Spr ing color s and dimensions have been provided in F igur e 20, however, ther e may be vari ations fr om model to model.. 15.Remove and discard the accumulator piston o-rings. C1 ACCUMULATOR LINE UP

C3 ACCUMULATOR LINE UP

16.Remove the anti-drain back check valve as shown in Figure 21. 17.Remove the B1 and B2 valvebody to case seals as shown in Figure 21. 18.Remove the B1 tube seal as shown in Figure 21. 19.Discard the B1 and B2 valvebody to case seals, and the B1 tube seal. Continued on Page 21

B3 ACCUMULATOR LINE UP O-RING

O-RING

VALVEBODY TO CASE SEAL B1

B1 BRAKE TUBE SEAL


O-RING O-RING

ACCUMULATOR SPRING

OUTSIDE DIAMETER

C1

18.5 mm (.728 in.)

90.53 mm (3.564 in.)

RED

C3

19.2 mm (.756 in.)

86.66 mm (3.411 in.)

WHITE

B3 INNER

15.9 mm (.626 in.)

60.24 mm (2.371 in.)

GREEN

B3 OUTER

16.7 mm (.657 in.)

72.61 mm (2.858 in.)

BLUE

FREE LENGTH

ID COLOR

ANTI-DRAIN BACK CHECK VALVE


Figure 20

20


Figure 21


Technical Service Information TRANSAXLEDISASSEMBLY(CONT’D) 20.Remove the manual shaft locating pin using a pair of pliers as shown in Figure 22. 21.Remove the bolts from the manual lever detent spring and the manual lever detent spring tensioner plate and remove the detent spring and tensioner plate as shown in Figure 23. 22.Remove the bolts from the park pawl lock bracket and remove the park pawl lock bracket as shown in Figure 23. 23.Use a small screwdriver to move the space r sleeve as shown in Figure 24.

24.Use a 1/8 in. diameter drift punch, to remove the roll pin from the manual selector shaft as shown in Figure 24. 25.Twist and remove the manual lever shaft from the case as shown in Figure 25. 26.Remove the manual valve detent lever and the park actuator rod as shown in Figure 25. 27.Remove the park actuator rod from the manual valve detent lever as shown in Figure 25.

Continued on Page 22.

SPACER SLEEVE MANUAL SHAFT LOCATING PIN

ROLL PIN



Figure 24

Figure 22 MANUAL LEVER DETENT SPRING TENSIONER PLATE

MANUAL VALVE DETENT LEVER

MANUAL LEVER SHAFT

MANUAL LEVER DETENT SPRING BOLT PARK ACTUATOR ROD REMOVE SHAFT FROM THE CASE IN THE DIRECTION OF THE ARROW.

PARK PAWL LOCK BRACKET

BOLTS


Figure 23


Figure 25


21

Technical Service Information TRANSAXLEDISASSEMBLY(CONT’D) 28.Remove the sixteen converter housing to case bolts as shown in Figure 26. 29.Once the bolts are removed, use a plastic hammer and gently tap the converter housing to loosen it from the transaxle case then remove the converter housing as shown in Figure 26. 30.Set the converter housing aside for component rebuild section. 31.Remove the final drive assembly by lifting straight up as shown in Figure 27. 32.Remove the seven oil pump retaining bolts as shown in Figure 28. 33.Remove the oil pump assembly by lifting straight up as shown in Figure 28. 34.Remove and discard the oil pump assembly o-ring as shown in Figure 28. Continued on Page 23. Copyr ight © 2009 ATSG

2

Figure 27

5 6 7

3 4

2. CONVERTER HOUSING TO CASE BOLTS (16 REQUIRED) 3. CONVERTER HOUSING ASSEMBLY 4. TRANSAXLE CASE ASSEMBLY

5. OIL PUMP ASSEMBLY O-RING 6. OIL PUMP ASSEMBLY 7. OIL PUMP RETAINING BOLTS (7 REQUIRED)


Figure 26

22


Figure 28


Technical Service Information TRANSAXLEDISASSEMBLY(CONT’D) 35.Using a pick or small screwdriver, remove and discard the two lube seals from the transaxle case assembly as shown in Figure 29. 36.Remove the thrust bearing and the bearing race from the underdrive planetary assembly as shown in Figure 29. 37.Remove and discard the forward (C1) clutch sealing ring as shown in Figure 30. 38.Remove the thrust bearing from the forward (C1) clutch drum as shown in Figure 30. 39.Remove the forward (C1) clutch drum assembly by lifting straight up as shown in Figure 30. 40.Remove the forward (C1) clutch thrust bearing assembly as shown in Figure 31. 41.Remove the forward (C1) clutch hub by lifting straight up as shown in Figure 31. 42.Remove the forward (C1) clutch hub thrust bearing and race as shown in Figure 31.

FORWARD (C1) CLUTCH SEALING RING

THRUST BEARING

FORWARD (C1) CLUTCH DRUM ASSEMBLY

Continued on Page 24. Copyr ight © 2009 ATSG

Figure 30 LUBE SEALS (2 REQUIRED) FORWARD (C1) CLUTCH THRUST BEARING ASSEMBLY UNDERDRIVE PLANET ASSEMBLY THRUST BEARING

UNDERDRIVE PLANET ASSEMBLY THRUST BEARING RACE

FORWARD (C1) CLUTCH HUB FORWARD (C1) CLUTCH HUB THRUST BEARING

FORWARD (C1) CLUTCH HUB THRUST BEARING RACE


Figure 29


Figure 31


23

Technical Service Information TRANSAXLEDISASSEMBLY(CONT’D) 43.Remove the park pawl shaft hold down bracket retaining bolt as shown in Figure 32. 44.Rotate the park pawl shaft hold down bracket and remove by sliding out and away from the park pawl shaft locating groove as shown in Figure 33. 45.Remove the park pawl shaft by lifting straight up as shown in Figure 33. 46.Slide the park pawl away from the park gear in the direction of the arrow as shown in Figure 34. Failure to do so will not allow removal of the underdrive planetary assembly.

PARK PAWL SHAFT

PARK PAWL SHAFT HOLD DOWN BRACKET



Figure 33

PARK PAWL SHAFT HOLD DOWN BRACKET RETAINING BOLT

SLIDE PARK PAWL AWAY FROM THE PARK GEAR IN THE DIRECTION OF THE ARROW


Figure 32

24


Figure 34


Technical Service Information TRANSAXLEDISASSEMBLY(CONT’D) 47.Remove the underdrive planetary assembly by lifting straight up as shown in Figure 35. The planetary assembly is heavy, use care when lifting. 48.Remove the park pawl return spring retaining pin from the case as shown in Figure 36. 49.Remove the park pawl return spring from the park pawl and remove from the case as shown in Figure 37. 50.Remove the park pawl from the case as shown in Figure 37.

PARK PAWL RETURN SPRING RETAINING PIN



Figure 36

PARK PAWL

UNDERDRIVE PLANETARY ASSEMBLY

PARK PAWL RETURN SPRING



Figure 35

Figure 37


25

Technical Service Information TRANSAXLEDISASSEMBLY(CONT’D) 51.Remove the underdrive clutch (C3) drum assembly from the case by lifting straight up as shown in Figure 38. 52.Remove the underdrive clutch (C3) thrust bearing and race assembly, and the underdrive clutch (C3) thrust bearing race as shown in Figure 38. 53.Using a screwdriver, remove the no. 2 one way clutch (F2) retaining snap ring as shown in Figure 39. 54.Remove the no. 2 one way clutch (F2) assembly from the case by lifting straight up as shown in Figure 39. 55.Remove the anti-rattle clip from the no. 2 one way clutch (F2) as shown in Figure 39. 56.Using a screwdriver, remove the underdrive brake retaining snap ring as shown in Figure 40. 57.Remove the underdrive brake (B3) pressure plate as shown in Figure 40. 58.Remove the underdrive brake (B3) friction and steel plates as shown in Figure 40. Continued on Page 27.

NO. 2 ONE WAY CLUTCH (F2) RETAINING SNAP RING ANTI-RATTLE CLIP

NO. 2 ONE WAY CLUTCH (F2)


Figure 39

UNDERDRIVE CLUTCH (C3) DRUM ASSEMBLY

UNDERDRIVE BRAKE (B3) RETAINING SNAP RING UNDERDRIVE BRAKE (B3) BACKING PLATE

UNDERDRIVE CLUTCH (C3) THRUST BEARING AND RACE ASSEMBLY

UNDERDRIVE BRAKE (B3) LINED PLATES (3 REQUIRED) UNDERDRIVE BRAKE (B3) STEEL PLATES (3 REQUIRED)

UNDERDRIVE CLUTCH (C3) THRUST BEARING RACE


Figure 38

26


Figure 40


Technical Service Information TRANSAXLEDISASSEMBLY(CONT’D) 59.Using SST 09387-00020 or a similar device and a suitable press, compress the underdrive brake (B3) piston return spring assembly, then using a pair of snap ring pliers remove the piston return spring retaining snap ring as shown in Figure 41. 60.Remove the underdrive brake (B3) piston return spring assembly as shown in Figure 41. 61.Remove the underdrive brake (B3) piston as shown in Figure 41. 62.Remove and discard the underdrive brake (B3) piston o-ring (inner) and (outer) as shown in Figure 41. 63.Remove and discard the underdrive clutch (C3) sealing rings as shown in Figure 42. 64.Turn transmission over so the transaxle rear cover is facing upward and remove the 11 12mm attaching bolts as shown in Figure 43. 65.Tap cover with a plastic hammer to loosen and remove the cover by lifting straight up as shown in Figure 43.

UNDERDRIVE CLUTCH (C3) SEALING RINGS 2 REQUIRED



Figure 42

PISTON RETURN SPRING RETAINING SNAP RING

TRANSAXLE REAR COVER ATTACHING BOLTS (11 REQUIRED)

UNDERDRIVE BRAKE (B3) PISTON RETURN SPRING

TRANSAXLE REAR COVER

UNDERDRIVE BRAKE (B3) PISTON

UNDERDRIVE BRAKE (B3) PISTON O-RING (INNER) UNDERDRIVE BRAKE (B3) PISTON O-RING (OUTER)

DIRECT CLUTCH (C2) THRUST BEARING



Figure 41

Figure 43


27

Technical Service Information TRANSAXLEDISASSEMBLY(CONT’D) 66.Remove the direct clutch (C2) thrust bearing as shown in Figure 43 on Page 27. Remove the 2 case seals as shown in Figure 44. 67.Remove the 10mm hold down bracket attaching bolt as shown in Figure 44. 68.Remove the feed tube hold down bracket as shown in Figure 44. 69.Using a screwdriver, gently loosen and remove the longer underdrive brake (B3) oil feed tube by lifting straight up as shown in Figure 44. 70.Using a screwdriver, gently loosen and remove the shorter underdrive clutch (C3) oil feed tube by lifting straight up as shown in Figure 44. 71.Remove the direct clutch (C2) assembly by lifting straight up as shown in Figure 45. 72.Remove the rear planetary sun gear thrust bearing race and the rear planetary sun gear thrust bearing as shown in Figure 46. 73.Remove the rear planetary sun gear assembly by lifting straight up as shown in Figure 46. 74.Remove the rear planetary sun gear washer as shown in Figure 46. Continued on Page 29.

DIRECT CLUTCH (C2) DRUM ASSEMBLY


Figure 45 REAR PLANETARY SUN GEAR THRUST BEARING RACE

HOLD DOWN BRACKET ATTACHING BOLT FEED TUBE HOLD DOWN BRACKET

REAR PLANETARY SUN GEAR THRUST BEARING

UNDERDRIVE BRAKE (B3) OIL FEED TUBE

REAR PLANETARY SUN GEAR ASSEMBLY

UNDERDRIVE CLUTCH (C3) OIL FEED TUBE

CASE SEALS (2 REQUIRED)

REAR PLANETARY SUN GEAR WASHER



Figure 44

28

Figure 46


Technical Service Information TRANSAXLEDISASSEMBLY(CONT’D) 75.Remove the No. 1 one way clutch (F1) thrust bearing as shown in Figure 47. 76.Remove the No. 1 one way clutch (F1) by lifting straight up as shown in Figure 47. 77.Remove the rear planetary thrust washer as shown in Figure 47. 78.Remove the No. 1 one way clutch (F1) outer sleeve by lifting the sleeve straight up as shown in Figure 48. 79.Using a screw driver, remove the 2nd brake (B1) retaining snap ring as shown in Figure 49. 80.Remove the 2nd brake (B1) steel and lined plates and the 2nd brake (B1) backing plate as shown in Figure 49.

NO. 1 ONE WAY CLUTCH F1 OUTER SLEEVE



Figure 48

2ND BRAKE (B1) RETAINING SNAP RING

NO 1 ONE WAY CLUTCH (F1) THRUST BEARING

2ND BRAKE (B1) BACKING PLATE

NO 1 ONE WAY CLUTCH (F1) 2ND BRAKE (B1) STEEL PLATES (4 REQUIRED)

2ND BRAKE (B1) LINED PLATES (4 REQUIRED)

REAR PLANETARY THRUST WASHER


Figure 47


Figure 49


29

Technical Service Information TRANSAXLEDISASSEMBLY(CONT’D) 81.Using a screwdriver, remove the 2nd brake (B1) apply piston housing retaining snap ring as shown in figure 50. 82.Remove the 2nd brake (B1) apply piston housing assembly by lifting straight up as shown in Figure 50. 83.Remove the first/reverse brake (B2) backing plate and the steel and lined plates as shown in Figure 51.

FIRST/REVERSE BRAKE (B2) BACKING PLATE (SELECTIVE)


FIRST/REVERSE BRAKE (B2) LINED PLATE (5 REQUIRED)

2ND BRAKE (B1) APPLY PISTON HOUSING RETAINING SNAP RING

2ND BRAKE (B1) APPLY PISTON HOUSING ASSEMBLY

FIRST/REVERSE BRAKE (B2) STEEL PLATE (5 REQUIRED)


Figure 50

30


Figure 51


Technical Service Information TRANSAXLEDISASSEMBLY(CONT’D) 84.Using a screwdriver, remove the rear planetary retaining snap ring as shown in Figure 52. 85.Remove the rear planetary assembly by lifting straight up as shown in Figure 52. 86.Remove the front planetary sun gear thrust bearing upper race, the front planetary sun gear thrust bearing, and the front planetary sun gear lower race as shown in Figure 53. 87.Remove the front planetary sun gear by lifting straight up as shown in Figure 53. 88.Remove the front planetary thrust bearing assembly as shown in Figure 53.

FRONT PLANETARY SUN GEAR THRUST BEARING UPPER RACE

FRONT PLANETARY SUN GEAR THRUST BEARING

FRONT PLANETARY SUN GEAR THRUST BEARING LOWER RACE


REAR PLANETARY RETAINING SNAP RING

FRONT PLANETARY SUN GEAR

FRONT PLANETARY THRUST BEARING ASSEMBLY

REAR PLANETARY ASSEMBLY


Figure 52


Figure 53


31

Technical Service Information TRANSAXLEDISASSEMBLY(CONT’D) 92.Using a hammer and suitable chisel, carefully un-stake the folded tabs on the locking washer as shown in Figure 54. 93.Using SST 09387-00030, 09387-00080 or a suitable drift punch, loosen the retaining nut by turning counter-clockwise as shown in Figure 54. 94.Remove the retaining nut and the retaining nut lock washer as shown in Figure 54. 95.Place transaxle housing in a suitable press, then using SST 09950-60010 (09951-00450) or a suitable bushing driver, carefully press the front planetary assembly through the counter drive gear as shown in Figure 55. 96.Once the front planetary assembly splines are pressed down and through the counter drive gear, remove the counter drive gear by lifting straight up as shown in Figure 56.

SST (SPECIAL SERVICE TOOL) 09950-60010 (09951-00450) OR SUITABLE BUSHING DRIVER



Figure 55 LOOSEN COUNTER CLOCKWISE

COUNTER DRIVE GEAR LOCKING TAB

RETAINING NUT

RETAINING NUT LOCK WASHER


Figure 54

32


Figure 56


Technical Service Information TRANSAXLEDISASSEMBLY(CONT’D) 97. Carefully remove the transaxle housing from the press and flip the transaxle housing over and remove the front planetary gear assembly by lifting straight up as shown in Figure 57. 98. Remove the front planetary ring gear and first/reverse brake (B2) hub assembly by lifting straight up as shown in Figure 57. 99. Remove the tapered roller bearing as shown in Figure 58. 100.Using a hammer and suitable drift punch, remove the two tapered roller bearing outer races from the case as shown in Figure 58. 101.Using a screwdriver, remove the snap ring from the case as shown in Figure 58.

TAPERED ROLLER BEARING

TAPERED ROLLER BEARING OUTER RACE


SNAP RING FRONT PLANETARY GEAR ASSEMBLY

FRONT PLANETARY RING GEAR/ FIRST/REVERSE BRAKE (B2) HUB ASSEMBLY




Figure 57

Figure 58


33

Technica echnicall Service Information Informa tion TRANSAXLEDIS ISASSEMBLY(CONT’D)

PISTON RETURN RETURN SPRING SPRING RETAINING SNAP RING

FIRST/REVERSE BRAKE (B2) PISTON RETURN SPRING

FIRST/REVERSE BRAKE (B2) PISTON

102.Using SST 09387-00070 or a similar device, a nd a suitable press, compress the first/reverse brake (B2) piston return spring and use a pair of o f snap ring pliers to remove the piston return spring retaining snap ring as shown in Figure 59. 103.Remove the first/reverse brake (B2) piston return spring as shown in Figure 59. 104.Remove the first/reverse brake (B2) apply piston as shown in Figure 59. 105.Remove and discard the first/reverse brake (B2) piston o-ring (inner) (inner) and and (outer) (outer) as as shown in Figure 59. Continued on Page 35.

ATSG TECHNICIA IANSDIA IAGNOSTICGUID IDE NOWAVAIL ILABLE, GETY TYOURSTODAY!!! !! CALL(3 (305) 670-4 -4161

FIRST/REVERSE BRAKE (B2) PISTON O-RING (INNER)

FIRST/REVERSE BRAKE (B2) PISTON O-RING (OUTER)

Copyr ight © 2009 ATSG ATSG

Figure 59

34


Technica echnicall Service Information Informa tion COMPONENTREBUIL ILD Torqu e Conve Converr te terr H ous ousin in g.

CONVERTER CO NVERTER HOUSING AXLE SEAL

1.

Using a screwdriver, or seal removal tool, carefully pry and remove the axle seal from the converter housing as shown in Figure 60. 2. Using an appropriate drift punch and a hammer, strike the back of the differential carrier tapered roller bearing race to unseat it from the case as shown in Figure 60. 3. Remove the differential carrier tapered roller bearing outer race from the case as shown in Figure 61.


DIFFERENTIAL DI FFERENTIAL CARRIER TAPERED ROLLER BEARING OUTER RACE

STRIKE BEARING RACE EVENLY HERE TO UNSEAT FROM CASE


Figure 60


Figure 61


35

Technica echnicall Service Information Informa tion COMPONENTR TREBUIL ILD(CONT’D) Torqu e Conve Converr te terr H ous ousin in g.

HOLD DOWN BRACKET RETAINING BOLT

LUBRICATION FEED TUBE HOLD DOWN BRACKET

LUBRICATION FEED TUBE

Using SST 09514-35011 or another suitable bearing removal tool such as a pilot bearing removal tool, remove the underdrive planetary assembly roller bearing as shown in Figure 62. 5. Remove the hold down bracket retaining bolt and the lubrication feed tube hold down bracket as shown in Figure 62. 6. Using a small screwdriver, carefully pry the lubrication feed tube from the case being be ing careful not to bend or crack the feed tube as shown in Figure 62. 7. Remove the underdrive planetary gear assembly lube seal as shown in Figure 63. 8. Clean all converter housing parts thoroughly and dry with compressed air air.. 9. Check the lube orifice cup plug for debris, and the two lube holes in the case by blowing a small amount of compressed air into the case as shown in Figure 63. 10. Install a new underdrive planetary gear assembly lube seal and coat with a small amount of Trans-Jel® as shown in Figure 63. 4.

Continued on Page 37. CHECK THE LUBE ORIFICE CUP PLUG FOR DEBRIS BLOCKING ORIFICE UNDERDRIVE PLANETARY ASSEMBLY ROLLER BEARING

UNDERDRIVE PLANETARY GEAR ASSEMBLY LUBE SEAL

LUBE HOLE AIR TEST HERE LUBE HOLE AIR TEST HERE


Figure 62

36


Figure 63


Technical Service Information COMPONENTREBUILD(CONT’D) Torqu e Converter H ousin g.

TORQUEBOLTTO 9.8 Nm(7ft. lb.)

HOLD DOWN BRACKET RETAINING BOLT

LUBRICATION FEED TUBE HOLD DOWN BRACKET

LUBRICATION FEED TUBE

11. Carefully inspect the lubrication feed tube for defect, replace as necessary and install into the torque converter housing as shown in Figure 64. 12. Install the lubrication feed tube hold down bracket and the hold down bracket retaining bolt and torque the bolt to 9.8 Nm(7ft. lb.) as shown in Figure 64. 13. Carefully inspect the underdrive planetary assembly roller bearing for defect, replace as necessary, and install roller bearing into the torque converter housing using SST 0995060020, (09951-00810), 09950-70010, (0995107100) or an appropriate bushing driver, then coat with a small amount of ATF as shown in Figure 64. 14. Inspect the differential carrier tapered roller bearing outer race for wear and replace as necessary, then install into the torque converter housing using SST 09951-00720, 09951-07150 or an appropriate bushing driver as shown in Figure 65. Continued on Page 38. DIFFERENTIAL CARRIER TAPERED ROLLER BEARING OUTER RACE

UNDERDRIVE PLANETARY ASSEMBLY ROLLER BEARING


Figure 64


Figure 65


37

Technical Service Information COMPONENTREBUILD(CONT’D) Torque Converter H ousin g. 15. Using a plastic hammer, with even taps, carefully install the torque converter housing axle seal into the case as shown in Figure 66. 16. Coat inside of axle seal with a small amount of Trans-Jel®. 17. Set aside the completed torque converter housing shown in Figure 67 for final assembly. Continued on Page 39.

TORQUE CONVERTER HOUSING AXLE SEAL

COMPLETEDTORQUECONVERTER HOUSINGASSEMBLY


Figure 66

38


Figure 67


Technical Service Information COMPONENTREBUILD(CONT’D) Un derdr ive Planetary Assembly.

UNDERDRIVEPLANETARYASSEMBLYEXPLODEDVIEW 1

2

5

9

3

6

4

7

10

11

1. UNDERDRIVE PLANETARY ASSEMBLY LOCKING NUT 2. UNDERDRIVE PLANETARY ROLLER BEARING INNER RACE 3. DIFFERENTIAL DRIVE PINION GEAR 4. PARKING LOCK GEAR 5. UNDERDRIVE PLANETARY ASSEMBLY TAPERED ROLLER BEARING 6. UNDERDRIVE PLANETARY ASSEMBLY TAPERED ROLLER BEARING INNER RACE ASSEMBLY

8

12

7. TAPERED ROLLER BEARING INNER RACE RETAINING SNAP RING 8. COUNTER DRIVEN GEAR 9. UNDERDRIVE PLANETARY ASSEMBLY TAPERED ROLLER BEARING 10. RETAINING SNAP RING 11. UNDERDRIVE PLANETARY RING GEAR 12. UNDERDRIVE PLANETARY ASSEMBLY GEAR SET


Figure 68


39

Technical Service Information COMPONENTREBUILD(CONT’D) Un derdri ve Planetar y Assembly UNDERDRIVE PLANETARY ASSEMBLY LOCKING NUT

BEND BACK STAKING HERE

Note: The under dri ve planetary r oller beari ng in ner r ace (2) and the dif ferenti al dri ve pini on gear (3) ar e pressed onto the plan etar y assembly gear set shaft ( see F igu r e 68). I t wi ll be necessary to use a press for disassembly an d reassembly. 1.

Using SST 09930-00010 (09931-00010, 0993100020) or an appropriate punch, bend back the staking on the underdrive planetary assembly locking nut as shown in Figure 69. 2. Set the underdrive planetary assembly into a soft jawed vice or similar holding device to avoid damage to the differential drive pinion gear, then using SST 09564-16020 or a suitable socket, remove the locking nut from the planetary assembly as shown in Figure 69. 3. Using SST 09950-00020, 09950-00030, 0995060010 (09951-00340) or a suitable bearing removal tool, remove the underdrive planetary roller bearing inner race as shown in Figure 70. Copyr ight © 2009 ATSG

Figure 69 UNDERDRIVE PLANETARY ROLLER BEARING INNER RACE


Figure 70

40



Technical Service Information COMPONENTREBUILD(CONT’D) Un derdri ve Planetar y Assembly

DIFFERENTIAL DRIVE PINION GEAR

4.

Using SST 09387-00050 or an equivalent support for the counter driven gear assembly and a press, press the underdrive planetary assembly gear set down through the counter driven gear assembly, then remove the differential drive pinion gear, parking lock gear, underdrive planetary assembly tapered roller bearing, and the counter driven gear assembly from the underdrive planetary assembly gear set as shown 5. in Figure 71. Using SST 09950-00020, 09950-00030, 0995060010 (09951-00340) or a suitable bearing removal tool, remove the underdrive planetary assembly tapered roller bearing as shown in Figure 72.

PARKING LOCK GEAR

UNDERDRIVE PLANETARY ASSEMBLY TAPERED ROLLER BEARING

Continued on Page 42. COUNTER DRIVEN GEAR ASSEMBLY UNDERDRIVE PLANETARY ASSEMBLY TAPERED ROLLER BEARING

UNDERDRIVE PLANETARY ASSEMBLY GEAR SET



Figure 71


Figure 72


41

Technical Service Information COMPONENTREBUILD(CONT’D)

Note:Do not attempt to r emove the tapered roll er beari ng in ner r ace assembly f rom the counter dr ive gear as shown i n th e un der dri ve plan etar y assembly expl oded view in F igur e 68. I t is not n ecessary dur in g over haul procedur e and damage may occur to ri ng gear or in ner race assembly. I f the taper ed r oll er beari ng in ner r ace assembly i s worn or pi tted, it wi ll be necessar y to r eplace the counter drive gear and in ner r ace as an assembly.

Un der dri ve Planetary Assembly 6.

The underdrive planetary ring gear can be removed from the counter drive gear by removing the snap ring as shown in Figure 73, however it is not necessary to remove unless there is damage to the underdrive planetary ring gear or counter drive gear. 7.

Clean all underdrive planetary assembly parts thoroughly and dry with compressed air. 8. Inspect all underdrive planetary assembly parts carefully and replace each as necessary. 9. Place the underdrive planetary assembly gea r set into a suitable press, then using SST 0931600011 or equivalent, install new tapered roller bearing onto the underdrive planetary assembly gear set and press into place as shown in Figure 74.

UNDERDRIVE PLANETARY RING GEAR ASSEMBLY

Continued on Page 43. UNDERDRIVE PLANETARY ASSEMBLY TAPERED ROLLER BEARING

RETAINING SNAP RING


COUNTER DRIVEN GEAR


Figure 73

42


Figure 74


Technical Service Serv ice Information Informat ion COMPONENTR TREBUIL ILD(CONT’D) Un de derr dri ve Planetar Planetar y Asse Assembly 10. With the underdrive planetary assembly gear set still in the suitable press, lubricate the tapered roller bearing inner race with a small amou nt of ATF and place the counter driven gear assembly on the underdrive planetary gear set as shown in Figure 75.

UNDERDRIVE PLANETARY ASSEMBLY ASSEMBL Y TAPERED TAPERED ROLLER BEARING

11. Install a new tapered roller bearing onto the counter driven gear assembly, then using SST 09316-00011 or equivalent, press the tapered roller bearing onto the underdrive planetary assembly gear set splines whi le at the same same time until the until slowl y tur ni ng the count count er dr iven gear gear tapered roller bearing is fully seated. 12. Using SST 09506-35010, 09950-60010 (0995100250) or equivalent, press the parking lock counter dr ive iven n gear gear and gear whil e turni ng the counter seat it against the tapered roller bearing as as shown in Figure 76. 13. Using SST 09506-35010, 09950-60010 (0995100250) or equivalent, press, the differential drive counter unter dri ve ven n pinion gear whil e tur nin g the co gear and seat it against the parking lock gear as shown in Figure 76. Continued on Page 44.

COUNTER DRIVEN GEAR ASSEMBLY ASSEMBL Y

UNDERDRIVE PLANETARY ASSEMBLY ASSEMBL Y GEAR SET SET


Figure 75


Figure 76


43

Technica echnicall Service Information Informa tion COMPONENTR TREBUIL ILD(CONT’D) Un de derr dri ve Planetar Planetar y Asse Assembly

UNDERDRIVE PLANETARY ROLLER BEARING INNER RACE


Figure 77

Counter Driv ivenGear Bearin ingPrelo load 0.7-- 4.4 Nm( 0.7 Nm(6.2 6.2- 38.9in. lb.) “STAKE” NUT INTO SHAFT HERE

14. Using SST 09506-35010, 09950-60010 (0995100250) or equivalent, press the underdrive turn ing planetary roller bearing inner race while turn the counter dri ve ven n ge gear ar and seat it against the and differential drive pinion gear as shown in Figure 77. 15. Set the underdrive planetary assembly into a soft jawed vice or similar holding device to avoid damage to the differential drive pinion gear then install a new locking nut using SST 0956416020 or a suitable socket and torque the locking nut to 280 N m (207 ft. lb.) as shown in Figure 78. 16. Using SST 09387-0050 or a similar holding device and SST 09564-16020 or a suitable socket and a torque wrench check the bearing preload of the underdrive planetary assembly Note:: Bea Note Bearr ing Preloa Preload d r efers to Turni ng Torr que 0.7 To 0.7 - 4.4 N m (6.2 - 38.9 in . lb.) 17. Once proper preload has been determined and correctly set, “stake” the nut into the shaft as shown in Figure 78. 18. Set the completed underdrive planetary assembly aside for final assembly assembly.. Refer to Figure 79. Component Rebuild Continued on Page 45.

COMPLETEDUNDERDRIV IVE PLA LANETARYASSEMBLY

UNDERDRIVE PLANETARY ASSEMBLY LOCKING NUT ASSEMBLY Torque: 280 N m (207 ft. lb.)



Figure 78

44

Figure 79


Technica echnicall Service Information Informa tion DIF IFFERENTIALEXPLODEDVIEW 2

11

8

5

10

6

9

9 8

4 7

10

3

11

2

1

1. DIFFERENTIAL RING GEAR. 2. DIFFERENTIAL TAPERED ROLLER BEARING (2 REQUIRED). 3. DIFFERENTIAL CARRIER ASSEMBLY. 4. DIFFERENTIAL CARRIER TO RING GEAR BOLT LOCKING PLATES (4 REQUIRED). 5. DIFFERENTIAL CARRIER TO RING GEAR BOLTS (8 REQUIRED). 6. DIFFERENTIAL CROSS SHAFT RETAINING PIN. 7. DIFFERENTIAL CROSS SHAFT. 8. DIFFERENTIAL SIDE GEAR THRUST WASHER. 9. DIFFERENTIAL SIDE GEAR. 10. DIFFERENTIAL PINION GEAR. 11. DIFFERENTIAL PINION GEAR THRUST WASHER.


Figure 80


45

Technical Service Information COMPONENTREBUILD(CONT’D) Di ff erenti al Assembly

FRONT TAPERED ROLLER BEARING

1.

Remove the front and rear differential tapered roller bearings using SST 09950-04011 (0995104010, 09952-04010, 09953-04030, 0995404010, 09955-04061, 09957-04010, 0995804011), 09950-60010 (09951-00440). Refer to Figure 81 for disassembly diagram. 2. Use a dial indicator and measure the backlash between the side gears and pinion gears as shown in Figure 82. (Backlash is referred to as the amount of free-play between the gears). 3. If backlash is not within specification, remove the cross shaft retaining pin and dissassemble the differential carrier assembly using the diagram in Figure 80 as a reference, and refer to thrust washer thickness chart in Figure 82 and select an appropriate washer to bring backlash into proper tolerance. Adjust until backlash is equal at both side gears. Note: I f r emovin g rin g gear f r om carr ier, both carr ier an d ri ng gear bol t hol es must be mark ed and matched for pr oper al ign ment dur ing r eassembly. Component Rebuild Continued on Page 47. THRUST WASHER THICKNESS: mm. (in.) 0.95 (0.0373) 1.00 (0.0393) 1.05 (0.0413) 1.10 (0.0433) 1.15 (0.0453) 1.20 (0.0472)

REAR TAPERED ROLLER BEARING

NOMINALSIDEGEARBACKLASH 0.05- 0.20 mm(0.002- 0.0008 in.)

10

0

10

20

20

30

30

40

40 50

46

50



Figure 81

0

Figure 82


Technical Service Information COMPONENTREBUILD(CONT’D) Di ff erenti al Assembly

4.

5.

FRONT TAPERED ROLLER BEARING

VEHICLE SPEED SENSOR DRIVE GEAR

6.

7.

8. 9.

Inspect and replace if necessary, the vehicle speed sensor drive gear (noting the direction of the gear) and install it onto the differential carrier as shown in Figure 83. Using SST 09350-32014 (09351-32150) or similar and a press, install the rear tapered roller bearing onto the differential carrier as shown in Figure 83. Using SST 09350-32014 (09351-32090, 0935132120) or similar and a press, install the front tapered roller bearing onto the differential carrier as shown in Figure 83. If ring gear removal was necessary to replace a defective ring gear, it may be necessary to heat the ring gear in a tank of hot water or parts washer to a temperature of 200 degrees before assembly. Note: I f r emovin g rin g gear f r om carr ier, both carr ier an d ri ng gear bol t hol es must be mark ed and matched for pr oper al ign ment dur ing r eassembly. Align the marks on the ring gear and carrier and quickly install the ring gear. Install new locking plates and the 8 bolts and torque the bolts to 96 N m (71 ft. lb.) then set the differential carrier aside for final assembly. Component Rebuild Continued on Page 48.

REAR TAPERED ROLLER BEARING

TORQUEBOLTSTO 96 Nm(71ft. lb.)



Figure 83

Figure 84


47

Technical Service Information OILPUMPASSEMBLY EXPLODEDVIEW

7

10 8

9

4 6

5

3 1 2

1. 2. 3. 4. 5.

OIL PUMP OIL PUMP OIL PUMP OIL PUMP OIL PUMP

CONVERTER SEAL CONVERTER HUB BUSHING BODY O-RING BODY BODY DRIVEN GEAR

6. OIL PUMP BODY DRIVE GEAR 7. OIL PUMP COVER/STATOR SHAFT ASSEMBLY 8. PUMP COVER TO PUMP BODY RETAINING BOLTS (11 REQUIRED) 9. OIL PUMP COVER/STATOR SHAFT ASSEMBLY ROLLER BEARING 10. OIL PUMP TEFLON SEALING RINGS (2 REQUIRED)


Figure 85

48


Technical Service Information COMPONENTREBUILD(CONT’D) Oil Pump A ssembly OIL PUMP BODY O-RING

1. 2. 3. 4. 5.

OIL PUMP CONVERTER SEAL

OIL PUMP CONVERTER HUB BUSHING

6.

7.

8.

9.


Figure 86

Disassemble the oil pump assembly using the diagram in Figure 85 as a guide. Remove the oil pump body o-ring and oil pump converter seal as shown in Figure 86. Remove the two pump body teflon sealing rings (if not previously done) as shown in Figure 87. Clean all oil pump parts thoroughly with solvent and dry with compressed air. Inspect all oil pump parts for wear or damage and replace as necessary. Check the oil pump driven gear to pump body clearance by using a feeler gauge between the driven gear and oil pump body as shown in Figure 88. Check the oil pump driven gear to pump body crescent clearance by using a feeler gauge between the driven gear and the oil pump body crescent as shown in Figure 88. Check the oil pump drive and driven gear side clearance using a straight edge and a feeler gauge as shown in Figure 88. If clearances are not within tolerance, replace oil pump assembly. Component Rebuild Continued on Page 50. DRIVEN GEAR TO OIL PUMP BODY CLEARANCE

OIL PUMP SEALING RINGS (2 REQUIRED)

0.075 - 0.150 m m (0.0030 - 0.0059 in.) LIMIT: 0.30 mm (0.0118 in.)

DRIVEN GEAR TO OIL PUMP BODY CRESCENT CLEARANCE

0.11 - 0.14 m m (0.0043 - 0.0055 in .) LIMIT: 0.30 mm (0.0118 in.)

DRIVE AND DRIVEN GEAR SIDE CLEARANCE

0.02 - 0.04 mm (0.0008 - 0.0016 in.) LIMIT: 0.10 m m (0.0039 in.)

FEELER GAUGE STRAIGHT EDGE



Figure 87

Figure 88


49

Technical Service Information COMPONENTREBUILD(CONT’D) Oil Pump A ssembly

OIL PUMP BODY DRIVEN GEAR

10. Using an appropriate bushing driver, install a new oil pump converter hub bushing as shown in Figure 89. 11. Using SST 09350-32014 (09351-32140) or other suitable seal installer, install a new oil pump converter seal as shown in Figure 89. 12. Install the oil pump body driven gear, the oil pump body drive gear and coat both gears with a small amount of ATF as shown in Figure 90. 13. Align the oil pump body with the oil pump cover and install the eleven pump cover to pump body retaining bolts as shown in Figure 91. 14. Using a torque wrench, torque the bolts to 9.8 N m (7 f t. lb.) as shown in Figure 91. 15. Install two new oil pump sealing rings onto the oil pump cover assembly and coat the rings with a small amount of Trans-Jel® as shown in Figure 91.

IDENTIFYING MARKS FACE UP

OIL PUMP BODY DRIVE GEAR


Figure 90

Component Rebuild Continued on Page 51.

TORQUE BOLTSTO 9.8 Nm(7ft. lb.)

OIL PUMP SEALING RINGS (2 REQUIRED) OIL PUMP CONVERTER SEAL

OIL PUMP CONVERTER HUB BUSHING



Figure 89

50

Figure 91


Technical Service Information COMPONENTREBUILD(CONT’D) Oil Pump A ssembly 16. Install a new oil pump body o-ring onto the oil pump assembly and coat with a small amount of Trans-Jel® as shown in Figure 92. 17. Set the completed pump assembly aside for final assembly as shown in Figure 93. Component Rebuild Continued on Page 52.

COMPLETEDPUMPASSEMBLY

OIL PUMP BODY O-RING



Figure 92

Figure 93


51

Technical Service Information DIRECT(C2) CLUTCH ASSEMBLY EXPLODEDVIEW

9 5

8 4

3

2

7

6

1

1. DIRECT (C2) CLUTCH DRUM ASSEMBLY 2. DIRECT (C2) CLUTCH PISTON ASSEMBLY 3. DIRECT (C2) CLUTCH PISTON RETURN SPRING 4. DIRECT (C2) CLUTCH BALANCE PISTON ASSEMBLY 5. DIRECT (C2) CLUTCH PISTON RETURN SPRING RETAINING SNAP RING 6. DIRECT (C2) CLUTCH STEEL PLATE (3 REQUIRED) 7. DIRECT (C2) CLUTCH LINED PLATE (3 REQUIRED) 8. DIRECT (C2) CLUTCH BACKING PLATE 9. DIRECT (C2) CLUTCH DRUM RETAINING SNAP RING


Figure 94

52


Technical Service Information COMPONENTREBUILD(CONT’D) 1.

Di rect (C2) Cl utch D ru m Assembly

2. 5

3. 4

4.

5. 6. 3

7.

8. 2

Disassemble the direct (C2) clutch drum assembly using Figure 94 as a guide. Clean all direct (C2) parts thoroughly with solvent and dry with compressed air. Inspect all direct (C2) clutch parts for wear and/or damage and replace as necessary. Coat the seal surface of the direct (C2) clutch piston with a small amount of Trans-Jel® and insert piston into the drum with a twisting motion as shown in Figure 95. Install the direct (C2) clutch piston return spring on top of the piston as shown in Figure 95. Coat the seal surface of the direct (C2) clutch balance piston with a small amount of Trans-Jel® and insert into the drum with a twisting motion as shown in Figure 95. Using SST 09387-00020 or similar device on the balance piston, compress the return spring gently using a suitable press and install the retaining snap ring as shown in Figure 95 Make sure the snap ring is fully seated in the snap ring groove and the balance piston as shown in Figure 96. Component Rebuild Continued on Page 54.

MAKE SURE SNAP RING IS FULLY SEATED IN SNAP RING GROOVE AND THE BALANCE PISTON

1

1. DIRECT (C2) CLUTCH DRUM ASSEMBLY 2. DIRECT (C2) CLUTCH PISTON ASSEMBLY 3. DIRECT (C2) CLUTCH PISTON RETURN SPRING 4. DIRECT (C2) CLUTCH BALANCE PISTON ASSEMBLY 5. DIRECT (C2) CLUTCH PISTON RETURN SPRING RETAINING SNAP RING



Figure 95

Figure 96


53

Technical Service Information COMPONENTREBUILD(CONT’D) Di rect (C2) Cl utch D ru m Assembly

RETAINING SNAP RING

DIRECT (C2) CLUTCH BACKING PLATE

DIRECT (C2) CLUTCH LINED PLATE (3 REQUIRED)

9.

Install the direct (C2) clutch plates beginning with a steel plate, then alternating frictions and steels until there are three steel and three lined plates installed into the drum housing as shown in Figure 97. Note: Al l F r icti on Plates shoul d be soaked in the appropr iate ATF for th e vehi cle for 30 minu tes pri or to i nstallation . 10. Install the direct (C2) clutch backing plate into the drum housing as shown in Figure 97. 11. Install the retaining snap ring into the drum housing as shown in Figure 97. 12. Check the direct (C2) clutch clearance using a feeler gauge between the backing plate and snap ring as shown in Figure 98. Note: D ir ect (C2) clutch cl earan ce shoul d be between 0.62mm - 0.74mm (.024” - .029”) 13. Change the “Selective” backing plate as necessary to attain proper clutch clearance using the chart in Figure 98. 14. Set completed direct (C2) clutch aside for final assembly. Component Rebuild Continued on Page 55. SELECTIVE BACKING PLATES AVAILABLE FROM DEALER. ORDER BY THICKNESS.

DIRECT (C2) CLUTCH STEEL PLATE (3 REQUIRED)

Di r ect (C2)Clutch Cl earance Shoul d Be 0.62mm - 0.74mm (.024" - .029”) Selective Di rect Clu tch B ackin g Plates 3.0mm (.118”)

3.3mm (.130”)

3.1mm (.122”)

3.4mm (.134”)

3.2mm (.126”)

3.5mm (.138”) Copyr ight © 2009 ATSG


Figure 97

54

Figure 98


Technical Service Information FORWARD(C1) CLUTCH ASSEMBLY EXPLODEDVIEW 9

5

8

4

7

3

2

11

1. FORWARD (C1) CLUTCH DRUM ASSEMBLY 2. FORWARD (C1) CLUTCH PISTON 3. FORWARD (C1) CLUTCH PISTON RETURN SPRING 4. FORWARD (C1) CLUTCH BALANCE PISTON 5. FORWARD (C1) CLUTCH PISTON RETAINING SNAP RING 6. FORWARD (C1) CLUTCH STEEL PLATE (4 REQUIRED)

10

6

1

1

7. FORWARD (C1) CLUTCH LINED PLATE (4 REQUIRED) 8. FORWARD (C1) CLUTCH BACKING PLATE 9. FORWARD (C1) CLUTCH DRUM RETAINING SNAP RING 10. FORWARD (C1) CLUTCH THRUST BEARING 11. FORWARD (C1) CLUTCH SEALING RING


Figure 99


55

Technical Service Information COMPONENTREBUILD(CONT’D) 1.

F orward (C1) Clu tch Dr um Assembly

2. 5

3. 4.

5. 4

6.

3

7.

8.

Disassemble the forward (C1) clutch drum assembly using Figure 99 as a guide. Clean all forward (C1) parts thoroughly with solvent and dry with compressed air. Inspect all forward (C1) clutch parts for wear and/or damage and replace as necessary. Coat the seal surface of the forward (C1) clutch piston with a small amount of Trans-Jel® and insert piston into the drum with a twisting motion as shown in Figure 100. Install the forward (C1) clutch piston return spring on top of the piston as shown in Figure 100. Coat the seal surface of the forward (C1) clutch balance piston with a small amount of Trans-Jel® and insert into the piston in the drum with a twisting motion as shown in Figure 100. Using SST 09320-89010 or similar device on the balance piston, compress the return spring gently using a suitable press and install the retaining snap ring as shown in Figure 100. Make sure the snap ring is fully seated in the snap ring groove and the balance piston as shown in Figure 101.

2

Component Rebuild Continued on Page 57. MAKE SURE SNAP RING IS FULLY SEATED IN SNAP RING GROOVE AND THE BALANCE PISTON

1

1. FORWARD (C1) CLUTCH DRUM ASSEMBLY 2. FORWARD (C1) CLUTCH PISTON ASSEMBLY 3. FORWARD (C1) CLUTCH PISTON RETURN SPRING 4. FORWARD (C1) CLUTCH BALANCE PISTON ASSEMBLY 5. FORWARD (C1) CLUTCH PISTON RETURN SPRING RETAINING SNAP RING



Figure 100

56

Figure 101


Technical Service Information COMPONENTREBUILD(CONT’D) F orward (C1) Clu tch Dr um Assembly

RETAINING SNAP RING

FORWARD (C1) CLUTCH BACKING PLATE

FORWARD (C1) CLUTCH LINED PLATE (4 REQUIRED)

9.

Install the forward (C1) clutch plates beginning with a steel plate, then alternating frictions and steels until there are four steel and four lined plates installed into the drum housing as shown in Figure 102. Note: Al l F r icti on Plates shoul d be soaked in the appropr iate ATF for th e vehi cle for 30 minu tes pri or to i nstallation . 10. Install the forward (C1) clutch backing plate into the drum housing as shown in Figure 102. 11. Install the retaining snap ring into the drum housing as shown in Figure 102. Check the forward (C1) clutch clearance using a feeler gauge between the backing plate and snap ring as shown in Figure 103. 12. Note: F orwar d (C1) clu tch clearance shoul d be between 0.61mm - 1.041mm (.024” - .041”) 13. Change the “Selective” backing plate as necessary to attain proper clutch clearance using the chart in Figure 103.

Component Rebuild Continued on Page 58. SELECTIVE BACKING PLATES AVAILABLE FROM DEALER. ORDER BY THICKNESS.

FORWARD (C1) CLUTCH STEEL PLATE (4 REQUIRED)


F orward (C1)Clu tch Clear ance Shoul d Be 0.61mm - 1.041mm (.024" - .041”) Selective F orwar d Clutch B ackin g Plates


Figure 102

3.0mm (.118”)

3.45mm (.135”)

3.15mm ( .124”)

3.6mm (.141”)

3.3mm (.130”)


Figure 103


57

Technical Service Information COMPONENTREBUILD(CONT’D) F orward (C1) Clu tch Dr um Assembly

FORWARD (C1) CLUTCH SEALING RING

14. Coat the thrust bearing with a small amount of Trans-Jel® and install the bearing into the drum as shown in Figure 104. 15. Install a new sealing ring into the drum and coat with a small amount of Trans-Jel® as shown in Figure 104. 16. Set the forward (C1) clutch drum aside for final assembly as shown in Figure 105.

FORWARD (C1) CLUTCH THRUST BEARING



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Figure 104

COMPLETED FORWARD(C1) CLUTCH DRUMASSEMBLY

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Figure 105

58


Technical Service Information UNDERDRIVE(C3) CLUTCH ASSEMBLY EXPLODEDVIEW 10

6

9

5

8

4

3

12

1. UNDERDRIVE (C3) CLUTCH DRUM ASSEMBLY 2. UNDERDRIVE (C3) CLUTCH DRUM O-RING SEAL 3. UNDERDRIVE (C3) CLUTCH PISTON ASSEMBLY 4. UNDERDRIVE (C3) CLUTCH PISTON RETURN SPRING 5. UNDERDRIVE (C3) CLUTCH BALANCE PISTON 6. UNDERDRIVE (C3) CLUTCH PISTON RETAINING SNAP RING

2

11

7

1

1

7. UNDERDRIVE (C3) CLUTCH STEEL PLATE (3 REQUIRED) 8. UNDERDRIVE (C3) CLUTCH LINED PLATE (3 REQUIRED) 9. UNDERDRIVE (C3) CLUTCH BACKING PLATE 10. UNDERDRIVE (C3) CLUTCH RETAINING SNAP RING 11. UNDERDRIVE (C3) CLUTCH THRUST BEARING AND RACE ASSEMBLY 12. UNDERDRIVE (C3) CLUTCH THRUST BEARING RACE


Figure 106


59

Technical Service Information COMPONENTREBUILD(CONT’D) Un der dri ve (C3) Clu tch Dr um Assembly

1. 2. 3. 4.

6

5.

5

6.

7.

4

8.

9. 3

Disassemble the underdrive (C3) clutch drum assembly using Figure 106 as a guide. Clean all underdrive (C3) parts thoroughly with solvent and dry with compressed air. Inspect all underdrive (C3) clutch parts for wear and/or damage and replace as necessary. Install a new o-ring for the underdrive (C3) clutch piston and coat with a small amount of Trans-Jel® as shown in Figure 107. Coat the seal surface of the underdrive (C3) clutch piston with a small amount of Trans-Jel® and insert piston into the drum with a twisting motion as shown in Figure 107. Install the underdrive (C3) clutch piston return spring on top of the piston as shown in Figure 107. Coat the seal surface of the underdrive (C3) clutch balance piston with a small amount of Trans-Jel® and insert into the piston in the drum with a twisting motion as shown in Figure 10 7. Using SST 09350-32014 (09351-32070) or similar device on the balance piston, compress the return spring gently using a suitable press and install the retaining snap ring as shown in Figure 107. Make sure the snap ring is fully seated in the snap ring groove and the balance piston as shown in Figure 108. Component Rebuild Continued on Page 61.

2

MAKE SURE SNAP RING IS FULLY SEATED IN SNAP RING GROOVE AND THE BALANCE PISTON

1

1. UNDERDRIVE (C3) CLUTCH DRUM ASSEMBLY 2. UNDERDRIVE (C3) CLUTCH DRUM O-RING SEAL 3. UNDERDRIVE (C3) CLUTCH PISTON ASSEMBLY 4. UNDERDRIVE (C3) CLUTCH PISTON RETURN SPRING 5. UNDERDRIVE (C3) CLUTCH BALANCE PISTON 6. UNDERDRIVE (C3) CLUTCH PISTON RETAINING SNAP RING



Figure 107

60

Figure 108


Technical Service Information COMPONENTREBUILD(CONT’D) Un der dri ve (C3) Clu tch Dr um Assembly

RETAINING SNAP RING

UNDERDRIVE (C3) CLUTCH BACKING PLATE

UNDERDRIVE (C3) CLUTCH LINED PLATE (3 REQUIRED)

10. Install the underdrive (C3) clutch plates beginning with a steel plate, then alternating frictions and steels until there are three steel and three lined plates installed into the drum housing as shown in Figure 109. Note: Al l F r icti on Plates shoul d be soaked in the appropr iate ATF for th e vehi cle for 30 minu tes pri or to i nstallation . 11. Install the underdrive (C3) clutch backing plate into the drum housing as shown in Figure 109. 12. Install the retaining snap ring into the drum housing as shown in Figure 109. Check the underdrive (C3) clutch clearance using a feeler gauge between the backing plate and snap ring as shown in Figure 110. 13. Note: U nderdr ive (C3) clut ch clearance shoul d be between 1.47mm - 1.69mm ( .057” - .067”) 14. Change the “Selective” backing plate as necessary to attain proper clutch clearance using the chart in Figure 110. 15. Set the underdrive (C3) clutch drum aside for final assembly. Component Rebuild Continued on Page 62. SELECTIVE BACKING PLATES AVAILABLE FROM DEALER. ORDER BY THICKNESS.

UNDERDRIVE (C3) CLUTCH STEEL PLATE (3 REQUIRED)

UNDERDRIVE (C3) CLUTCH DRUM ASSEMBLY

Un der dri ve (C3)Clutch Cl earance Should Be 1.47mm - 1.69mm (.057" - .067”) Selective Un derdri ve (C3) Cl utch B ackin g Plates Copyr ight © 2009 ATSG

Figure 109

3.0mm (.118”)

3.4mm (.134”)

3.2mm (.126”)


Figure 110


61

Technical Service Information 2NDBRAKE(B1) ASSEMBLYEXPLODEDVIEW

9. 4.

8.

3.

2.

1. 7.

6.

1. 2ND BRAKE (B1) PISTON HOUSING ASSEMBLY 2. 2ND BRAKE (B1) PISTON ASSEMBLY 3. 2ND BRAKE (B1) PISTON RETURN SPRING 4. 2ND BRAKE (B1) RETURN SPRING RETAINING SNAP RING 5. 2ND BRAKE (B1) PISTON HOUSING RETAINING SNAP RING 6. 2ND BRAKE (B1) BACKING PLATE 7. 2ND BRAKE (B1) LINED PLATES (4 REQUIRED) 8. 2ND BRAKE (B1) STEEL PLATES (4 REQUIRED) 9. 2ND BRAKE (B1) RETAINING SNAP RING

5.


Figure 111

62


Technical Service Information COMPONENTREBUILD(CONT’D) 2nd Br ake (B1) Clu tch Assembly 1.

2. 3. 4.

5.

6. 7. 8.

Disassemble the 2nd brake (B1) clutch piston assembly using the diagram in Figure 111 as a guide. Clean all 2nd brake (B1) clutch parts thoroughly with solvent and dry with compressed air. Inspect all 2nd brake (B1) clutch parts for wear and/or damage and replace as necessary. Install a new inner and outer o-ring onto the 2nd brake (B1) piston assembly and coat the o-rings with a small amount of Trans-Jel® as shown in Figure 112. Carefully install 2nd brake (B1) piston into the piston housing with a twisting motion as shown in Figure 113. Install the 2nd brake (B1) piston return spring as shown in Figure 114. Install the 2nd brake (B1) piston return spring retaining snap ring as shown in Figure 114. Make sure snap ring is fully seated in the snap ring groove, and set 2nd brake (B1) piston assembly aside for final assembly. Component Rebuild Continued on Page 64.

2ND BRAKE (B1) PISTON

2ND BRAKE (B1) PISTON HOUSING


Figure 113 2ND BRAKE (B1) RETURN SPRING RETAINING SNAP RING

2ND BRAKE (B1) OUTER O-RING

2ND BRAKE (B1) PISTON RETURN SPRING

2ND BRAKE (B1) INNER O-RING

2ND BRAKE (B1) PISTON


Figure 112


Figure 114


63

Technical Service Information NO. 1ONEWAY CLUTCH(F1) 7.

3.

6.

2.

5.

1. 4.

1. NO. 1 ONE-WAY CLUTCH (F1) RETAINING PLATE (LOWER) 2. NO. 1 ONE-WAY CLUTCH (F1) END BEARING (LOWER) 3. NO. 1 ONE-WAY CLUTCH (F1) ONE-WAY CLUTCH OUTER RACE 4. NO. 1 ONE-WAY CLUTCH (F1) ONE-WAY CLUTCH ASSEMBLY 5. NO. 1 ONE-WAY CLUTCH (F1) END BEARING (UPPER) 6. NO. 1 ONE-WAY CLUTCH (F1) ONE-WAY CLUTCH INNER RACE 7. NO. 1 ONE-WAY CLUTCH (F1) RETAINING PLATE (UPPER)


Figure 115

64


Technical Service Information NO. 2ONEWAY CLUTCH(F2)

4.

7.

3. 6.

2.

5.

1.

1. NO. 2 ONE-WAY CLUTCH (F2) RETAINING PLATE (LOWER) 2. NO. 2 ONE-WAY CLUTCH (F2) END BEARING (LOWER) 3. UNDERDRIVE BRAKE (B3) ANTI-CLUNK SPRING 4. NO. 2 ONE-WAY CLUTCH (F2) ONE-WAY CLUTCH OUTER RACE 5. NO. 2 ONE-WAY CLUTCH (F2) ONE-WAY CLUTCH ASSEMBLY 6. NO. 2 ONE-WAY CLUTCH (F2) END BEARING (LOWER) 7. NO. 2 ONE-WAY CLUTCH (F2) RETAINING PLATE (LOWER)


Figure 116


65


NO. 1 ONE-WAY CLUTCH (F1) ASSEMBLY

No. 1 One-Way Clu tch ( F 1) Assembly 1.

2.

3.

4.

5.

Disassemble the No. 1 one-way clutch (F1) assembly using the diagram in Figure 115 as a guide. Clean all No. 1 one-way clutch (F1) assembly parts thoroughly with solvent and dry with compressed air. Inspect all No. 1 one-way clutch (F1) assembly parts for wear and/or damage and replace as necessary. Install the retaining plate (lower) to the No. 1 one-way clutch (F1) outer race and snap into place as shown in Figure 117. Install the end bearing (lower) into the No. 1 one-way clutch (F1) outer race as shown in Figure 117. Component Rebuild Continued on Page 67.

NO. 1 ONE-WAY CLUTCH (F1) OUTER RACE

LIP FACING UP

ID GROOVE FACING UP

Copyr ight © 2009 ATSG NO. 1 ONE-WAY CLUTCH (F1) END BEARING (LOWER)

Figure 118 NO. 1 ONE-WAY CLUTCH (F1) RETAINING PLATE (UPPER)

NO. 1 ONE-WAY CLUTCH (F1) OUTER RACE NO. 1 ONE-WAY CLUTCH (F1) END BEARING (UPPER)

NO. 1 ONE-WAY CLUTCH (F1) RETAINING PLATE (LOWER)


Figure 117

66


Figure 119



HOLDOUTERRACE INNERRACEFREEWHEELS “COUNTER-CLOCKWISE”

No. 1 One-Way Clu tch ( F 1) Assembly 6.

Coat the No. 1 one-way clutch (F1) assembly with a small amount of ATF, and install into the No. 1 one-way clutch (F1) outer race as shown in Figure 118. NOTE : M ake sur e the LI P on th e one way clutch and the I D GROOVE on th e outer r ace are both f acing th e same upwar d dir ection as shown i n F igur e 118. 7. Install the No. 1 one-way clutch (F1) upper end bearing as shown in Figure 119. 8. Install the No. 1 one-way clutch (F1) retaining plate and then snap it into place as shown in Figure 119. 9. Install the No. 1 one-way clutch (F1) inner race by twisting in a “counter clockwise” direction with the bearing seat facing upward as shown in Figure 120. 10. Check freewheel operation of the No. 1 one-way clutch (F1) as shown in Figure 121. (H old the outer r ace, and the inn er r ace shoul d . freewheel i n a “count er-clockwi se” di rection)

HOLD


Figure 121



NO. 1 ONE-WAY CLUTCH (F1) INNER RACE

BEARING SEAT FACES UPWARD

NO. 2 ONE-WAY CLUTCH (F2) RETAINING PLATE (LOWER)

NO. 2 ONE-WAY CLUTCH (F2) END BEARING (LOWER)


Figure 120


Figure 122


67

Technical Service Information COMPONENTREBUILD(CONT’D) No. 2 One-Way Clu tch ( F 2) Assembly 1.

2.

3.

4.

5.

6.

7.

Disassemble the No. 2 one-way clutch (F2) assembly using the diagram in Figure 116 as a guide. Clean all No. 2 one-way clutch (F2) assembly parts thoroughly with solvent and dry with compressed air. Inspect all No. 2 one-way clutch (F2) assembly parts for wear and/or damage and replace as necessary. Install the retaining plate (lower) to the No. 2 one-way clutch (F2) outer race and snap into place as shown in Figure 122. Install the end bearing (lower) into the No. 2 one-way clutch (F2) outer race as shown in Figure 122. Coat the No. 2 one-way clutch (F2) with a small amount of ATF and install into the No. 2 oneway clutch (F2) outer race (making sure the lip on the one way clutch and the id mark on the inner race are facing upward) as shown in Figure 123. Install the No. 2 one-way clutch (F2) upper end

8.

Install the No. 2 one-way clutch (F2) retaining plate and then snap it into place as shown in Figure 124. 9. Install the anti-clunk spring into place as shown in Figure 124. 10. Check freewheel operation of the No. 2 one-way clutch (F2) as shown in the transaxle final assembly section Figure 198. (With the No. 2 one-way clutch (F 2) installed in the case with the id marks facing upward, the underdrive clutch (C3) drum should freewheel in a “ counter clockwise” direction). Continued on Page 69. NO. 2 ONE-WAY CLUTCH (F2) RETAINING PLATE (UPPER)

NO. 2 ONE-WAY CLUTCH (F2) ASSEMBLY

NO. 2 ONE-WAY CLUTCH (F2) END BEARING (UPPER)

LIP FACING UP



ID MARKS FACING UP

ANTI-CLUNK SPRING


Figure 123

68


Figure 124


Technical Service Information COMPONENTREBUILDSECTION VALVEBODYASSEMBLY 1.

2.

3. .

Remove the three, 10 mm bolts identified with the letter "A," and remove the S4, SL2 and DSL solenoids from their bores, and lay aside for later inspection as shown in Figure 125. Remove the two, 8 mm bolts identified with the letter "B," and remove the SL1 and SLT solenoids from their bores, and lay aside for later inspection as shown in Figure 125. Remove the 8 mm bolt identified with the letter "B," and remove the relief spring and ball retainer as shown in Figure 125. Note: retain er is spri ng l oaded.

4.

5. 6.

Remove relief spring and ball and lay aside for cleaning and assembly as shown in Figure 125. Note: Bal l di ameter is 10mm. Remove the seven 10mm bolts identified with the letter "C" as shown in Figure 125. Remove the Manual Valve and lay aside for further cleaning and inspection.

Valve body assembly continued on Page 70.

SOLENOIDANDVALVEBODY BOLTREMOVALIDENTIFICATION MANUAL VALVE SHIFT SOLENOID VALVE S4 “SOLENOID D”

A

C C

SHIFT SOLENOID VALVE SL2 “SOLENOID B”

C

A C

A SHIFT SOLENOID VALVE DSL “LOCKUP SOLENOID”

B C

RELIEF SPRING AND BALL RETAINER

B B SHIFT SOLENOID VALVE SL1 “SHIFT SOLENOID A”

SOLENOID VALVE SLT “LINE PRESSURE SOLENOID”

Bolt Lenghts BoltA=45mm. (1.770in.) BoltB=12mm. (.450in.) Bolt C=41mm. (1.614 in.) Copyr ight © 2009 ATSG

Figure 125


69

Technical Service Information COMPONENTREBUILDSECTION VALVEBODYASSEMBLY(CONT’D) 7.

Remove the seven, 10 mm bolts identified with the letter "D" as shown in Figure 126. 8. Remove the 10 mm bolt identified with the letter "E" as shown in Figure 126 9. Remove the six, 8 mm bolts identified with the letter "F" as shown in Figure 126. 10. Remove the remaining 8 mm bolt identified with the letter "G" and remove the cover as shown in Figure 126.

11. Using snap-ring pliers, remove the snap rings retaining the B1and C2 accumulator lineups as shown in Figure 126. Caution: both assemblies ar e spr ing l oaded. 12. Remove the B1 and C2 accumulator assembly retaining washers, springs and pistons, as shown in Figure 126 and lay aside for later inspection.

Valve body assembly continued on Page 71. B1 Accumulator Assembly Retaining Snap-ring C2 Accumulator Assembly Washer

F

Retaining Snap-ring

D

Washer

D B1 Accumulator Springs

C2 Accumulator Springs

G

F

D

D

D B1 Accumulator Piston

E

C2 Accumulator Piston

D

F F F GASKET COVER

Bolt Lengths Bolt D =41mm.(1.614 in.) Bolt E =30mm.(1.181in.) Bolt F=14mm. (.551in.) BoltG=10mm. (.394 in.) Figure 126

70



Technical Service Information COMPONENTREBUILDSECTION VALVEBODYASSEMBLY(CONT’D) 13. Remove the 10 mm bolt identified with the letter "D" and remove the retainer and 10 mm relief ball as shown in Figure 127. 14. Remove the remaining 10 mm relief ball that is now exposed, after the removal of the cover. 15. Place fingers on the spacer plate, where the two grey arrows are indicated, and thumbs on the upper valve body, retaining them together, and flip the plate and valve body bottom side up as shown in Figure 127.

16. Remove the spacer plate from the upper valve body as shown in Figure 128. 17. Remove the two screens, and the five 5.5mm (.217") check balls as shown in Figure 128. 18. Set upper valve body aside for cleaning and further dis-assembly.


D Relief Ball

Relief Ball and retainer Spacer plate

Upper Valve body Spacer plate

p i l F

Screen

UPPERVALVEBODY CHECKBALLLOCATIONS

5.5 mm (.217") Check ball

Spacer plate

Screen


Upper Valve body

Bolt Lengths Bolt D=41mm.(1.614 in.)



Figure 127

Figure 128


71

Technical Service Information COMPONENTREBUILDSECTION VALVEBODYASSEMBLY(CONT’D) 19. Remove the Cooler relief valve and spring from the lower valve body as shown in Figure 129. 20. Remove the five 5.5 mm (.217") check balls as shown in Figure 129.

21. Remove the 5.5 mm (.217") check ball from the left corner of the lower valve body as shown in Figure 129 if required. Note: wi ll only use a ball in thi s location i f there is a hol e in the spacer plate above it.


LOWER VALVEBODY CHECKBALLLOCATIONS Not Used on all Models (HOLE IN PLATE TAKES A BALL NO HOLE IN PLATE, NO BALL)

Cooler Relief Valve and Spring



Figure 129

72


Technical Service Information COMPONENTREBUILDSECTION VALVEBODYASSEMBLY(CONT’D)

24. Assemble the lower valve body parts as shown in Figure 130, and lube the valves with a small amount of ATF as they are installed. Note: the main r egul ator boost sleeve is adju stable and should be mar ked before removal to ensure that i t i s back at the factor y adjustment. Th is wil l af fect L in e Pressur e. Al so, thi s sleeve is commonl y worn and may requi re r eplacement.

22. Disassemble lower valve body and place valves, springs and retainers in appropriate trays exactly as they were removed as shown in Figure 130. 23. Clean all valve body parts thoroughly with solvent and dry with compressed air.


LOWER VALVEBODY

22 21

20

19 18

15

16 14 17

12 13

11

4 3

1

.078" cross drilled orifice

10 9

2 8 7 6

LOWER VALVEBODYLEGEND 1. C2 Control Valve retainer 2. C2 Control Valve bore plug 3. C2 Control Valve 4. C2 Control Valve spring 5. Main Regulator Valve retainer 6. Main Regulator Valve Plug 7. Main Regulator Valve Boost Sleeve 8. Main Regulator Valve Boost Valve 9. Main Regulator Valve Spring 10. Main Regulator Valve Spring Seat 11. Main Regulator Valve

5

Sleeve is adjustable mark position before removal

12. B-2 Control Valve retainer 13. B-2 Control Valve bore plug 14. B-2 Control Valve 15. B-2 Control Valve Spring 16. B-1 Control Valve retainer 17. B-1 Control Valve bore plug 18. B-1 Control Valve 19. B-1 Control Valve spring 20. 3-4 Shift Valve retainer 21. 3-4 Shift Valve spring 22. 3-4 Shift Valve


Figure 130


73

Technical Service Information COMPONENTREBUILDSECTION VALVEBODYASSEMBLY(CONT’D) 25. Disassemble upper valve body and place valves, springs and retainers in appropriate trays exactly as they were removed as shown in Figure 131. 26. Clean all valve body parts thoroughly with solvent and dry with compressed air. Inspect the accumulator bores on top of the upper valve body for any wear and replace the valve body as necessary.

27. Assemble the upper valve body parts as shown in Figure 131, and lube the valves with a small amount of ATF as they are installed. Note: I tems 49 and 32 are commonl y worn and may r equi re replacement. A lso note there are dif ferent l engths on some of th e retain ers li sted below i n F igu re 131. Valve body assembly continued on Page 75.

60 61 48

62 49

53 50

54

59 56

44

52

45

46 47

40 41

63

58 55

51

UPPERVALVEBODY

57

42 43

39 35

Reta iner Lengths 8 mm

10 mm

21

36 31 23 27

60 53 44

38

34 33

30

31 29 26

Accumulator bores

UPPERVALVEBODYLEGEND

23. C2 Lock Valve retainer 24. C2 Lock Valve bore plug 25. C2 Lock Valve 26. C2 Lock Valve Spring 27. Secondary Regulator Valve retainer 28. Secondary Regulator Valve bore plug 29. Secondary Regulator Valve 30. Secondary Spring 31. Lock-up Control Valve retainer 32. Lock-up Control Valve Sleeve 33. Lock-up Control Valve Spring 34. Lock-up Control Valve Plunger 35. Lock-up Control Valve 36. Lock-up Relay Valve retainer 37. Lock-up Relay Valve bore plug 38. Lock-up Relay Valve Spring 39. Lock-up Relay Valve 40. 3 Way Check Valve Retainer 41. 3 Way Check Valve outer ball seat 42. 3 Way Check Valve .250" steel ball 43. 3 Way Check Valve inner ball seat

37

32 27

23

25

40

36

24

28

44. C2 Exhaust Valve retainer 45. C2 Exhaust Valve bore plug 46. C2 Exhaust Valve Spring 47. C2 Exhaust Valve 48. Clutch Apply Control Valve retainer 49. Clutch Apply Control Valve Sleeve 50. Clutch Apply Control Valve plunger 51. Clutch Apply Control Valve Spring 52. Clutch Apply Control Valve 53. B-1 Lock Valve retainer 54. B-1 Lock Valve bore plug 55. B-1 Lock Valve Spring 56. B-1 Lock Valve 57. B-3 Orifice Control Valve retainer 58. B-3 Orifice Control Valve Spring 59. B-3 Orifice Control Valve 60. Solenoid Modulator Valve retainer 61. Solenoid Modulator Valve bore plug 62. Solenoid Modulator Valve 63. Solenoid Modulator Spring


Figure 131

74


Technical Service Information COMPONENTREBUILDSECTION VALVEBODYASSEMBLY(CONT’D) 28. Refer to Figure 132 below to check the SLT, line pressure control solenoid and its mechanical function. Figure 132 also will indicate the ohm value of the solenoid as well as a hydraulic description of the solenoids function. 29. Refer to Figure 133 to check the SL1 solenoid and its mechanical function. Figure 133 will also show the ohm value and its hydraulic function. 30. Refer to Figure 134 to check the SL2 solenoid and its mechanical function. Figure 134 will also show the ohm value and its hydraulic function.

31. Refer to Figure 135 to check the S4 solenoid and its mechanical function. Figure 135 will also show the ohm value and its hydraulic function. 32. Refer to Figure 136 to check the DSL solenoid and its mechanical function. Figure 136 will also show the ohm value and its hydraulic function.


SLTLINEPRESSURECONTROLSOLENOID

4.5-6.0 Ohms

To 2ndary Reg. Valve Spri ng side, B-3 Or if ice Contr ol Valve and the Pr imar y Reg. Boost Valve

X X

Solenoid M odul ating Pressure

NORM ALLY APPLI ED The SL T or L in e Pressur e Contr ol Solenoi d is a Nor mall y Appli ed li near type Solenoid. When the Solenoid i s OF F Solenoid M odulati ng Pr essur e will be connected to the port l eading to th e 2ndar y Reg. Valve Spr in g side, B-3 Or ifice Control Valve and the Primar y Reg. Boost Valve causing Pr essur e to be hi gh i n th ose cir cuit s, as well as M ain L in e Pressur e. When the SL T Solenoi d is ON pr essur e will be low leadin g to the valves li sted above, as well as L in e Pressur e. Th is Solenoi d is contr oll ed by the PCM whi ch calcul ates the duty cycle to match L in e Pressur e to engi ne load.


Figure 132


75

Technical Service Information COMPONENTREBUILDSECTION VALVEBODYASSEMBLY(CONT’D) 4.5-6.0


SL1 SOLENOID

Ohm s

To L ockup Contr ol valve and the B-1 L ock Valve Spri ng side in 2nd Gear

X

Solenoid M odulating Pressure Norm a lly App lied

Th e SL 1 Solenoid is a Nor mall y Appli ed li near type Solenoid. When the Solenoid is OFF M odulati ng Pressur e will be connected to the port leadin g to the L ockup Contr ol valve and the spri ng side of the B-1 lock valve. When the Solenoid i s ON M odulati ng pr essur e wil l be blocked. Copyr ight © 2009 ATSG

Figure 133

4.5-6.0 Oh m s

SL2 SOLENOID To the spr in g side of the C2 lock valve, C2 exhaust valve and th e C-2 contr ol valve

X X

Solenoid M odul ating Pressure

Norm a lly App lied

Th e SL 2 Solenoid is a Nor mall y Appli ed li near type Solenoid. When the Solenoid is OFF M odulati ng Pressur e will be connected to the port leadin g to the spri ng side of the C2 L ock Valve, the fi rst l and of t he C2 exhau st valve and the fi r st l and of t he C2 Control valve. Copyr ight © 2009 ATSG

Figure 134

76


Technical Service Information COMPONENTREBUILDSECTION VALVEBODYASSEMBLY(CONT’D)


S4 SOLENOI D OF F

ON

F orward Clutch Pressur e from M anual valve

F orward Clutch Pressur e from M anual valve

Blocked To 3-4 Shi ft Valve

Connected To 3-4 Shi ft Valve

11-15 Ohm s

Norm a lly Closed

The S4 Solenoid is a Norm all y Closed Solenoid. When OF F it bl ocks F orwar d Clutch pr essur e fr om str okin g the 3-4 Shi ft Valve. When ON it conn ects F orwar d Clut ch pressur e to the F ir st lan d of the 3-4 Shi ft Valve str okin g the valve to the r igh t makin g the 3-4 upshi ft tr ansiti on. Copyr ight © 2009 ATSG

Figure 135

OFF

DSL - TCC SOLE NOID

Solenoid M odul ating Pressure Blocked To B-2 Control valve or L ockup relay valve

ON Solenoid M odulating Pressure

Connected To B-2 Control valve or L ockup relay valve

D W 3 0 A

DA W 3 0

11-15 Ohm s

Norm a lly Closed

The DSL /TCC Solenoid is a Nor mall y Closed Solenoid. When OF F it bl ocks Solenoid modulati ng pressur e from the F ir st land of t he B-2 Contr ol valve in Reverse, 1st and 2nd gear, and the L ockup relay valve in 3rd an d 4th gear. When ON i t connects Solenoid M odulati ng pr essur e to the B-2 contr ol valve whi ch wil l apply the B2 clu tch f or engin e braki ng in M anual low, and also connects Solenoid M odulati ng pr essur e to the L ockup r elay valve when i n 3r d and 4th gears to apply th e TCC. Note: I f stuck open, may cause No Reverse, engi ne braki ng i n D rive 1st gear and a Bi nd on th e 1-2 shi ft. Copyr ight © 2009 ATSG

Figure 136


77

Technical Service Information COMPONENTREBUILDSECTION VALVEBODYASSEMBLY(CONT’D) 33. Install the five - 5.5mm (217") check balls into the lower valve body casting as shown below in Figure 137. Note: check the spacer plate over the check ball pocket in the top left corn er t o ver if y whether it requi r es the check ball . 34. Install the cooler relief spring and valve into the lower valve body as shown in Figure 138. 35. Install the five - 5.5mm (217") check balls into the upper valve body casting as shown below in Figure 138. 36. Install new o-rings onto the two screens and lubricate with a small amount of Trans-Jel® then install into the two holes in the upper valve body in the locations shown in Figure 138. 37. Assemble the spacer plate onto the upper valve body as shown in Figure 138, so it can be installed as an assembly onto the lower valve body.

Spacer plate

Screen

"O"-ring

UPPER VALVEBODY


Valve body assembly continued on Page 79. "O"-ring

LOWER VALVEBODY Screen Not Used on all Models (hole in plate takes a ball no hole in plate, no ball).


Cooler Relief Valve and Spring

Spacer plate

Upper Valve body 5.5 mm (.217") Check ball

Copyr ight © 2009 2008 ATSG


Figure 137

78

Figure 138


Technical Service Information COMPONENTREBUILDSECTION VALVEBODYASSEMBLY(CONT’D) 38. Place fingers on the spacer plate, where the two grey arrows are indicated, and thumbs on the upper valve body, retaining them together, as shown in Figure 139. 39. Flip the plate and valve body over and assemble it onto the Lower Valve body, as shown in Figure 139.

40. Install the two 10 mm relief balls into the uppe r valve body as shown in Figure 139. 41. Install the retainer and the bolt identified with the letter “D" as shown in Figure 139, but do not torque at this time. 42. Install a new gasket on the Upper Valve body and assemble the cover over the new gasket as shown in Figure 140. Valve body assembly continued on Page 80.

Spacer plate COVER

GASKET

Upper Valve body

Upper Valve body

p i l F

Lower Valve body

D Relief Ball and retainer


Relief Ball

Figure 140

Upper Valve body Spacer plate

Lower Valve body

Bolt Lengths Bolt D=41mm.(1.614 in.)


Figure 139


79

Technical Service Information COMPONENTREBUILDSECTION VALVEBODYASSEMBLY(CONT’D) 43. Install the seven, 10 mm bolts identified with the letter "D." Torque all bolts identified with the letter "D" to 11 Nm, 8f t.lb. See Figure 141. 44. Install the 10 mm bolt identified with the letter "E." Torque the bolt identified with the letter "E" to 11Nm, 8ft.l b . See Figure 141. 45. Install the six, 8 mm bolts identified with the letter "F," and the remaining 8 mm bolt identified with the letter "G" and torque to 6.6 Nm, 58in.lb. See Figure 141. B1 Accumulator Outer Spring

B1 Accumulator Inner Spring

No. Coils-10 Overall Length-1.765" Outside Diameter- .632" Coil Diameter- .082" Color- White

Retaining Snap-ring

No. Coils-13.5 Overall Length-1.725" Outside Diameter- .432" Coil Diameter- .059" Color- Purple

46. Inspect the B1 and C2 accumulator pistons for wear or scoring, replace as necessary, and install them into the upper valve body as shown in Figure 141. 47. Install the accumulator springs into the pistons and verify the correct springs are in their locations, by using the spring specs provided in Figure 141. 48. Install the washer and retaining snap-ring as shown in Figure 141. Valve body assembly continued on Page 81. C2 Accumulator Outer Spring

C2 Accumulator Inner Spring

No. Coils-9.5 Overall Length-1.845" Outside Diameter- .633" Coil Diameter- .078" Color- Red-Brpwn

No. Coils-11.5 Overall Length-1.860" Outside Diameter- .438" Coil Diameter- .050" Color- Red-Brown

B1 Accumulator Assembly C2 Accumulator Assembly

Washer

F

Retaining Snap-ring

D C2 Accumulator Springs

G

D

D

D D

C2 Accumulator Piston

B1 Accumulator Piston

E F

Washer

B1 Accumulator Springs

D

D F

Upper Valve body

F F GASKET COVER

Bolt LengthsandTorqueSpecs Bolt D=41mm.(1.614 in.) Torque- 11Nm,8ft.lb Bolt E =30mm.(1.181in.) Torque- 11Nm,8ft.lb BoltF=14mm. (.551in.) Torque- 6.6Nm, 58in.lb Bolt G=10mm. (.394in.) Torque- 6.6Nm,58in.lb

Figure 141

80



Technical Service Information COMPONENTREBUILDSECTION VALVEBODYASSEMBLY(CONT’D) 49. Install the seven 10 mm bolts identified with the letter "C," and torque to 11Nm, 8ft.l b. See Figure 142. 50. Install the S4, SL2 and DSL solenoids into their bores, and install the bolts identified with the letter"A," and torque to 11Nm, 8ft.l b. as shown in Figure 142. 51. Install the SL1 and SLT solenoids into their bores, and the two, 8 mm bolts identified with . the letter "B," and torque to 6.6 Nm, 58 in .lb . as shown in Figure 142.

52. Install relief ball into the valve body then install the spring, retainer and bolt identified with the letter "B" and torque to 6.6 Nm, 8ft.lb. as shown in Figure 142. Note: Bal l di ameter i s 10mm. 53. Install the Manual valve as shown in Figure 142.


SOLENOIDANDVALVEBODY BOLTINSTALLATIONIDENTIFICATION MANUAL VALVE SHIFT SOLENOID VALVE S4 “SOLENOID D”

A

C C

SHIFT SOLENOID VALVE SL2 “SOLENOID B”

C

A C

A SHIFT SOLENOID VALVE DSL “LOCKUP SOLENOID”

B C

RELIEF SPRING AND BALL RETAINER

B B SHIFT SOLENOID VALVE SL1 “SHIFT SOLENOID A”

Relief Spring and ball removed

SOLENOID VALVE SLT “LINE PRESSURE SOLENOID”

BoltLengthsandTorqueSpecs Bolt A=45mm. (1.770 in.) Torque- 11Nm, 8ft.lb Bolt B =12mm. (.450 in.)Torque- 6.6 Nm, 58in.lb Bolt C=41mm. (1.614in.) Torque- 11Nm, 8ft.lb Copyr ight © 2009 ATSG

Figure 142


81

Technical Service Information FINALASSEMBLY I nter nal components 1.

Clean the case thoroughly and dry with compressed air. 2. Install the snap ring into the snap ring groove in the case as shown in Figure 143. 3. Using SST 09950-60020 (09951-00890), 0995070010 (09951-07150) or other suitable tool, press the tapered roller bearing outer races into the case until they both make contact with the snap ring as shown in Figure 143. 4. Coat the tapered roller bearing with a small amount of ATF, then using SST 09649-17010 or other suitable tool, press the tapered roller bearing onto the counter drive gear until it contacts the gear as shown in Figure 144.

5.

Coat the tapered roller bearing with a small amount of ATF, then use SST 09950-60010 (09951-00890), 09950-70010 (09951-07150) or other suitable tool and a press to install the counter drive gear and the tapered roller bearing into the case, or set the case in a suitable press, and while supporting the counter drive gear press the tapered roller bearing over the counter drive gear as shown in Figure 145. Final Assembly Continued on Page 83.


COUNTER DRIVE GEAR


RETAINING SNAP RING


Figure 144




Figure 143

82


Figure 145


Technical Service Information FINALASSEMBLY I nter nal components 6.

7.

8.

Install a new outer and inner o-ring onto the first/reverse brake (B2) piston as shown in Figure 146, and coat the o-rings with a small amount of Trans-Jel®. Install the first/reverse brake (B2) piston into the case by twisting and pushing downward as shown in Figure 147. Install the piston return spring into the piston as shown in Figure 148.

9.

Using SST 09387-00070 or similar, and a press, compress the piston return spring and install the retaining snap ring as shown in Figure 148. 10. Make sure snap ring is fully seated into the groove as shown in Figure 149. Final Assembly Continued on Page 84.


FIRST/REVERSE BRAKE (B2) PISTON

FIRST/REVERSE BRAKE (B2) PISTON RETURN SPRING

FIRST/REVERSE BRAKE (B2) PISTON O-RING (INNER)

FIRST/REVERSE BRAKE (B2) PISTON O-RING (OUTER)


Figure 146 Copyr ight © 2009 ATSG FIRST/REVERSE BRAKE (B2) PISTON

Figure 148 MAKE SURE SNAP RING IS FULLY SEATED IN THE GROOVE


Figure 147


Figure 149


83

Technical Service Information FINALASSEMBLY I nter nal components 11. If the front planetary ring gear/first/reverse brake (B2) hub has been disassembled, inspect and clean all parts thoroughly with solvent, then dry with compressed air and reassemble using the diagram in Figure 150 as a guide. 12. Install the front planetary into the hub and install into the case as shown in Figure 151. 13. Using SST 09950-60010 (09951-00400) or other suitable tool and a press, align the splines of the front planet and the counter drive gear and press the front planet into the counter drive gear, or set the case into a suitable tool, and while supporting the counter drive gear, press the front planetary splines into the counter drive gear using a suitable driver as shown in Figure 152. Note: Do not u se excessive f or ce when pr essing the fr ont plan etary i nto the counter dr ive gear.

FRONT PLANETARY GEAR ASSEMBLY

FRONT PLANETARY RING GEAR/ FIRST/REVERSE BRAKE (B2) HUB ASSEMBLY

Final Assembly Continued on Page 85. FRONTPLANETARYRINGGEAR/ FIRST/REVERSEBRAKE(B2) HUB ASSEMBLYEXPLODEDVIEW FIRST/REVERSE BRAKE (B2) HUB


Figure 151

FRONT PLANETARY INTERNAL RING GEAR

BEVELED SIDE OF RING GEAR GOES INTO THE HUB

DRIVER SHOULD BE POSITIONED IN CENTER OF PLANETARY WHERE BEARING CONTACT AREA IS LOCATED

RETAINING SNAP RING


Figure 150

84

NOTE: DO NOT USE EXCESSIVE FORCE WHEN PRESSING PLANETARY INTO COUNTER DRIVE GEAR


Figure 152


Technical Service Information FINALASSEMBLY I nter nal components 14. Flip the case housing over and install the counter drive gear retaining nut lock washer as shown in Figure 153. 15. Install the counter drive gear retaining nut as shown in Figure 153. 16. Use SST 09387-00030, 09387-00080 or other suitable socket and torque the retaining nut to 280 N m (207 ft. lb.) as shown in Figure 154. 17. Bend retaining nut locking tabs and stake them into place as shown in Figure 154. 18. Install the front planetary thrust bearing with the lip down as shown in Figure 155. 19. Install the front planetary sun gear as shown in Figure 155. 20. Install the thrust bearing lower race with the lip down and the bearing as shown in Figure 155. 21. Install the thrust bearing upper race as shown in Figure 155. If necessary, use a small amount of Trans-Jel® to hold the bearing in place.

RETAINING NUT

RETAINING NUT LOCK WASHER

Final Assembly Continued on Page 86. FRONT PLANETARY SUN GEAR THRUST BEARING UPPER RACE


Figure 153 FRONT PLANETARY SUN GEAR THRUST BEARING

TIGHTENCLOCKWISE INDIRECTIONOF ARROW ANDTORQUETO 280 Nm(207ft. lb.)

FRONT PLANETARY SUN GEAR THRUST BEARING LOWER RACE

BEND LOCKING TABS UPWARD AND STAKE INTO PLACE

FRONT PLANETARY SUN GEAR FRONT PLANETARY THRUST BEARING ASSEMBLY


Figure 154


Figure 155


85

Technical Service Information FINALASSEMBLY I ntern al components 22. Install the rear planetary as shown in Figure 156. 23. Install the rear planetary retaining snap ring using a screwdriver as shown in Figure 156. 24. Make sure snap ring is fully seated into the snap ring groove as shown in Figure 157. 25. Install the first/reverse brake (B2) clutch plates into the case beginning with a steel plate, then alternating frictions and steels until there are five steel plates and five lined plates in the case as shown in Figure 158.

26. Install the first/reverse brake (B2) backing plate (selective) as shown in Figure 158. Note: f r icti on pl ates shoul d be soaked in the appropri ate atf f or th e vehi cle for 30 min utes pri or to in stallation. Final Assembly Continued on Page 87.

FIRST/REVERSE BRAKE (B2) BACKING PLATE (SELECTIVE)

REAR PLANETARY RETAINING SNAP RING

REAR PLANETARY ASSEMBLY FIRST/REVERSE BRAKE (B2) LINED PLATE (5 REQUIRED)


Figure 156 FIRST/REVERSE BRAKE (B2) STEEL PLATE (5 REQUIRED)

MAKE SURE SNAP RING IS FULLY SEATED INTO SNAP RING GROOVE


Figure 157

86


Figure 158


Technical Service Information FINALASSEMBLY I ntern al components 27. Check the first/reverse brake (B2) clutch clearance as shown in Figure 159. 28. Clutch clearance or piston travel should be 1.1 - 1.24 mm (.043 - .048 in .) and is determined by using a vernier caliper and measuring the distance from the top friction plate to the seat in the case where the 2nd brake (B1) housing sits. Once the measurement is taken it can be referred to as “Dimension A”. The thickness of the first/reverse brake (B2) backing plate is then measured and subtracted from “Dimension A”. With this number, the proper selective backing plate can be determined and installed into the case according to the chart in Figure 159. 2ND BRAKE (B1) HOUSING SEAT (IN CASE)

0 0 . 9 4 5

Final Assembly Continued on Page 88.

TOP FRICTION PLATE

SNAP RING CROSS SECTION VIEW

BEVEL SIDE FACES UPWARD

SELECTIVE BACKING PLATES AVAILABLE FROM DEALER. ORDER BY THICKNESS.

I N

29. Install the 2nd brake (B1) piston housing assembly into the transmission aligning the lugs into the case with the feed hole toward the valve body area of the case as shown in Figure 160. 30. Install the 2nd brake (B1) piston housing retaining snap ring with the bevel side facing upward as shown in Figure 160. 31. Make sure retaining snap ring is fully seated into the snap ring groove in the case.

2ND BRAKE (B1) APPLY PISTON HOUSING RETAINING SNAP RING

MEASURE DISTANCE WITH CALIPER

2ND BRAKE (B1) APPLY PISTON HOUSING ASSEMBLY

F ir st/Reverse Br ake (B2) Clu tch Cl earan ce/Piston Tr avel 1.10 - 1.24mm (.043 - .048”) Selective F irst/Rever se Br ake Backi ng Plates 1.8 mm (.071”)

2.2 mm (.087”)

1.9 mm (.075”)

2.3 mm (.091”)

2.0 mm (.079”)

2.4 mm (.094”)

2.1 mm (.083”)

2.5 mm (.098”) Copyr ight © 2009 ATSG

Figure 159


Figure 160


87

Technical Service Information FINALASSEMBLY I nter nal components


32. Coat the rear planetary thrust washer with a small amount of Trans-Jel® and install into the locating holes in the rear planetary as shown in Figure 161. 33. Install the No. 1 one way clutch (F1) outer sleeve so that the narrow lugs fit into the locating slots in the 2nd brake (B1) piston housing assembly as shown in Figure 162. 34. Install the No. 1 one way clutch (F1) assembly so it fits into the lugs in the outer shell as shown in Figure 163. 35. Make sure the id groove on the one way clutch assembly is facing up (toward the back cover) when installed as shown in Figure 163. Final Assembly Continued on Page 89.


Figure 161 WIDE LUGS

NO. 1 ONE WAY CLUTCH (F1) OUTER SLEEVE

NO 1 ONE WAY CLUTCH (F1)

ID GROOVE FACES UPWARD

NARROW LUGS


Figure 162

88


Figure 163



NO. 1ONEWAYCLUTCH(F1) INNERRACEMUSTFREEWHEEL COUNTER-CLOCKWISEINTHE DIRECTIONOFTHEARROW

36. The one way clutch inner race must freewheel counter-clockwise as shown in Figure 164. 37. Coat the No. 1 one way clutch (F1) thrust bearing with a small amount of Trans-Jel® and install it in the direction shown in Figure 165. 38. Coat the rear planetary thrust washer with a small amount of Trans-Jel® and install it into the rear planetary sun gear assembly. 39. Install the rear planetary sun gear assembly using a twisting motion as shown in Figure 166. 40. Coat the rear planetary sun gear thrust bearing with a small amount of Trans-Jel® and install onto the rear planetary sun gear as shown in Figure 166. Final Assembly Continued on Page 90.

REAR PLANETARY SUN GEAR THRUST BEARING


Figure 164

REAR PLANETARY SUN GEAR ASSEMBLY

NO 1 ONE WAY CLUTCH (F1) THRUST BEARING



Figure 165


Figure 166


89


2ND BRAKE (B1) RETAINING SNAP RING

2ND BRAKE (B1) BACKING PLATE

41. Install the 2nd brake (B1) clutch plates into the case beginning with a steel plate, then alternating frictions and steels until there are four steel plates and four lined plates in the case as shown in Figure 167. Note: Al l F ricti on Plates shoul d be soaked in the appropr iate ATF for the vehi cle for 30 min utes pri or to i nstallation . 42. Install the 2nd brake (B1) backing plate and the retaining snap ring as shown in Figure 167. 43. Make certain retaining snap ring is fully seated in the snap ring groove as shown in Figure 168. 44. Check clutch clearance to determine appropriate backing plate thickness as shown in Figure 168. 45. Note: 2nd br ake (B1) cl utch cl earan ce shoul d be between .024 - .028” if not wi thi n specif icati on, select appr opriate backin g plate fr om chart in F igure 168. Final Assembly Continued on Page 91.

2ND BRAKE (B1) LINED PLATES (4 REQUIRED)

SELECTIVE BACKING PLATES AVAILABLE FROM DEALER. ORDER BY THICKNESS.

MAKE SURE SNAP RING IS FULLY SEATED IN THE SNAP RING GROOVE

2ND BRAKE (B1) STEEL PLATES (4 REQUIRED)

2nd Br ake (B1) Clu tch Cl earan ce/Piston Tr avel .62 - .73mm (.024 - .028”) Selective 2nd Br ake Backing Plates 3.0 mm (.118”)

3.4 mm (.134”)

3.1 mm (.122”)

3.5 mm (.138”)

3.2 mm (.126”)

3.6 mm (.142”)

3.3 mm (.130”) Copyr ight © 2009 ATSG


Figure 167

90

Figure 168


Technical Service Information FINALASSEMBLY I nter nal components 46. Coat the rear planetary sun gear thrust bearing race with a small amount of Trans-Jel® and install it into the direct (C2) clutch drum assembly as shown in Figure 169. 47. Install the direct (C2) clutch drum assembly into the case with a twisting motion so the clutches in the drum spline onto the rear planetary sun gear assembly as shown in Figure 169. 48. Coat the direct (C2) clutch thrust bearing with a small amount of Trans-Jel® and install onto the drum as shown in Figure 169. 49. Lay a straight edge across the direct (C2) clutch drum on top of the bearing and measure the distance from the case to the top of the straight edge. Deduct the height of the straight edge from the overall height to obtain ”Dimension A” as shown in Figure 170. 50. Measure the distance from the bearing seat in the rear cover to the top of the ring tower as shown in Figure 171. This is (“Dimension 1”).

51. Measure from the top of the ring tower to the area where the rear cover contacts the transaxle case. This is “Dimension 2”. Deduct (“Dimension 2”) from (“Dimension 1”) to determine “Dimension “B”. Next, deduct “Dimension A” from “Dimension B”. Using this number, choose the appropriate thrust washer from the chart below to obtain proper end play as shown in Figure 171. Final Assembly Continued on Page 92. OBTAINING“DIMENSIONA” “Dimension A” is obtained by measuring from the top of the straight edge to the transmission case and deducting the height of the straight edge from the total measurement.

0 1 .2 4 5

I N

DIRECT (C2) CLUTCH THRUST BEARING

DIRECT (C2) CLUTCH DRUM ASSEMBLY


Figure 170 OBTAINING“DIMENSIONB” “Dimension B” is obtained by measuring from the bearing seat in the housing to the top of the ring tower (“ Dimension 1”) and then measuring from the top of the ring tower to the area where the cover contacts the transaxle case (“Dimension 2”). Deduct (“Dimension 2”) from (“Dimension 1”) to determine “Dimension “B”.

REAR PLANETARY SUN GEAR THRUST BEARING RACE

DIMENSION 1

DIMENSION 2

SELECTIVE BEARINGSAVAILABLE FROM DEALER. ORDER BY THICKNESS.

END PLAY 0.2 - 0.9mm (.008 - .035 in.) THICKNESS

I NSI DE DI A.

OUTSI DE DI A.

3.55 mm (.139”)

53.6 mm (2.11”)

69.6 mm (2.74”)

3.85 mm (.151”)

53.6 mm (2.11”)

69.6 mm (2.74”)



Figure 169

Figure 171


91

Technical Service Information FINALASSEMBLY I nter nal components 52. Inspect the rear cover needle bearing and if replacement is necessary, remove using SST 09387-00040 (09387-01010, 09387-01030, 09387-01040) or another similar bearing puller using Figure 172 as a reference. 53. Install new needle bearing (if replacing) using SST 09950-60010 (09951-00230, 09951-00350) or a similar driver and a press and install the new bearing to a depth of 12.05 - 12.75mm (.474 - .502 in.) using Figure 172 as a reference. NEEDLEBEARINGDEPTH 12.05 - 12.75 MM(.474 - .502 in.) REAR COVER BEARING

54. Install two new rings onto the back cover and coat the rings with a small amount of Trans-Jel® as shown in Figure 173. 55. Make certain the rings overlap correctly as shown in Figure 173. 56. Install the U/D clutch (C3) oil feed tube with a small plastic hammer as shown in Figure 174. 57. Install the U/D brake (B3) oil feed tube with a small plastic hammer as shown in Figure 174. Note: Use care when i nstall ing tu bes so they do not get bent or damaged in any way. 58. Install the two case seals using a small amount of Trans-Jel® to keep the seals in place as shown in Figure 174. 59. Install the feed tube hold down bracket as shown in Figure 174. 60. Install the feed tube hold down bracket attaching bolt as shown in Figure 174. Final Assembly Continued on Page 93. HOLD DOWN BRACKET ATTACHING BOLT FEED TUBE HOLD DOWN BRACKET


Figure 172

U/D BRAKE (B3) OIL FEED TUBE

U/D CLUTCH (C3) OIL FEED TUBE

CASE SEALS (2 REQUIRED) REAR COVER SEALING RINGS (2 REQUIRED)


Figure 173

92


Figure 174


Technical Service Information FINALASSEMBLY I ntern al components TRANSAXLE REAR COVER ATTACHING BOLTS (11 REQUIRED)

61. Using a torque wrench, torque the hold down bracket attaching bolt to 5.4 N m (48 in . lb.) as shown in Figure 175. 62. Apply a thin bead of FIPG Part No. 0882600090, THREE BOND 1281 or equivalent anaerobic sealant to the perimeter of the rear cover. 63. Coat the inside of the rear cover needle bearing with a small amount of ATF. 64. Install the transaxle rear cover onto the transaxle case as shown in Figure 176. 65. Apply a very small amount of liquid sealant Part No. 08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent anaerobic sealant to the rear cover attaching bolt “A”, then install the attaching bolts as shown in Figure 177. 66. Using a torque wrench, torque the rear cover attaching bolt “A” to 18.6 N m (14 ft. l b.) and attaching bolts “B” to 24.5 N m ( 18 ft. lb.) as shown in Figure 177.

TRANSAXLE REAR COVER



Figure 176

HOLDDOWNBRACKET ATTACHINGBOLTTORQUE 5.4 Nm(48 in. lb.)

REARCOVER ATTACHINGBOLTB (TENREQUIRED) TORQUE 24.5 Nm(18 ft. lb.)

REARCOVER ATTACHINGBOLTA (ONEREQUIRED) TORQUE 18.6 Nm(14 ft. lb.)


Figure 175


Figure 177


93

Technical Service Information FINALASSEMBLY I nter nal components 67. Using a plastic hammer, with even taps, carefully install the torque converter housing axle seal into the case as shown in Figure 178. 68. Coat inside of axle seal with a small amount of Trans-Jel®. 69. Flip the transaxle housing over then coat the differential tapered roller bearings with a small amount of ATF and place the differential carrier into the case as shown in Figure 179. 70. Install the sixteen differential housing to transaxle case attaching bolts and torque them as shown in Figure 180.

DIFFERENTIAL TAPERED ROLLER BEARING RACE

Final Assembly Continued on Page 95. Copyr ight © 2009 ATSG

Figure 179 B

A

TRANSAXLE CASE AXLE SEAL

A

C

BOLT

LENGTH

TORQUE

BOLTA: (7REQUIRED) BOLTB: (4 REQUIRED) BOLTC: (5REQUIRED)

42 mm(1.654 in.) 50mm(1.969in.) 50mm(1.969in.)

29Nm(22ft. lb.) 29Nm(22ft. lb.) 22Nm(16 ft. lb.)


Figure 178

94


Figure 180


Technical Service Information FINALASSEMBLY I nter nal components 71. Using SST 09564-32011 or similar device, turn the differential carrier in the case back and forth several times to allow the bearings to fully settle in the case as shown in Figure 181. 72. Using SST 09564-32011 or similar device and a torque wrench, measure differential preload as shown in Figure 181. 73. Compare the measured preload with the chart in Figure 182. 74. If preload is not within specification, remove transaxle tapered roller bearing race (refer to Figure 179) and select a differential spacer from the chart in Figure 182 to obtain specified preload. 75. Once preload is within specification, remove the differential housing attaching bolts and the housing as shown in Figure 183. NOTE : Selective spacer s avail able fr om the dealer, or der by thi ckness. Final Assembly Continued on Page 96.

CHECKING DIFFERENTIALPRELOAD USING SST 09564-32011 OR A SIMILAR DEVICE ROTATE DIFFERENTIAL CARRIER BACK AND FORTH SEVERAL TIMES IN ORDER TO FULLY SEAT THE BEARINGS THEN CHECK THE PRELOAD

DIF FERENTIAL PRELOAD New Beari ng 1.0 - 1.6 N m (8.7 - 14.2 in . lb.) Reused Beari ng 0.5 - 0.8 N m ( 4.4 - 7.1 in. l b.) DI FF ERENTIAL SPACER THI CKNESS 2.90 mm (.1141 in.)

3.40 mm (.1339 in.)

2.95 mm (.1161 in .)

3.45 mm (.1358 in .)

3.00 mm (.1181 in .)

3.50 mm (.1378 in .)

3.05 mm (.1201 in.)

3.55 mm (.1398 in .)

3.10 mm (.1220 in.)

3.60 mm (.1417 in .)

3.15 mm (.1240 in.)

3.65 mm (.1437 in .)

3.20 mm (.1260 in.)

3.70 mm (.1457 in .)

3.25 mm (.1279 in.)

3.75 mm (.1476 in .)

3.30 mm (.1299 in.)

3.80 mm (.1496 in .)

3.35 mm (.1319 in.)


Figure 182


Figure 181


Figure 183


95


TRANSAXLE CASE NEEDLE BEARING


76. Inspect the needle bearing in the transaxle case and remove (if necessary) using SST 0938700040, (09387-01020,09387-01030, 0938701040) or a similar bearing puller. Refer to Figure 184 for reference. 77. Install new bearing (if necessary) using SST 09950-60010, (09951-00320), 09950-70010 (09951-07100) or a similar driver and install the needle bearing into the transaxle case as shown in Figure 185. 78. Use a dial caliper to obtain proper bearing depth in the case. Refer to Figure 185 for reference. 79. Coat the needle bearing with a small amount of ATF. 80. Install two new underdrive clutch (C3) sealing rings onto the ring support in the transaxle case as shown in Figure 186. 81. Make sure the rings lock together as shown in Figure 186. Note: B e careful not to open th e rin gs too far, or damage to the ri ngs may resul t. 82. Coat the new rings with a small amount of Trans-Jel®.

Figure 184 Final Assembly Continued on Page 97.

PRESSBEARINGINTOCASETOADEPTHOF 12.05 - 12.75 Nm(0.474 - 0.502in.)

UNDERDRIVE CLUTCH (C3) SEALING RINGS (2 REQUIRED)

0 0 .4 8 5 I N


Figure 185

96


Figure 186


Technical Service Information FINALASSEMBLY I nter nal components 83. Install a new inner and outer o-ring onto the underdrive brake (B3) piston and coat both orings with a small amount of Trans-Jel® as shown in Figure 187. 84. Using a twisting motion, install the underdrive brake (B3) piston into the case as shown in Figure 187. 85. Make sure piston is fully seated into the case. Install the underdrive brake (B3) piston return spring into the piston as shown in Figure 188. 86. Using SST 09387-00020 or similar and a suitable press, compress the piston return spring as shown in Figure 188. 87. Using a pair of snap ring pliers, install the piston return spring retaining snap ring as shown in Figure 188. 88. Make certain the snap ring is fully seated into the snap ring groove as shown in Figure 189.


UNDERDRIVE BRAKE (B3) PISTON RETURN SPRING


Figure 188

UNDERDRIVE BRAKE (B3) PISTON MAKE CERTAIN SNAP RING IS FULLY SEATED IN THE SNAP RING GROOVE

UNDERDRIVE BRAKE (B3) PISTON O-RING (INNER) UNDERDRIVE BRAKE (B3) PISTON O-RING (OUTER)


Figure 187


Figure 189


97

Technical Service Information FINALASSEMBLY I nter nal components 89. Install the underdrive brake (B3) clutch plates into the case beginning with a steel plate, then alternating frictions and steels until there are three steel plates and three lined plates in the case as shown in Figure 190. Note: Al l F ricti on Plates shoul d be soaked in the appropr iate ATF for the vehi cle for 30 min utes pri or to i nstallation . 90. Install the underdrive brake (B3) backing plate into the case as shown in Figure 191. 91. Install the underdrive brake (B3) retaining snap ring as shown in Figure 191. 92. Make certain the retaining snap ring is fully seated in the snap ring groove as shown in Figure 192. 93. Check clutch clearance/piston travel using a dial indicator while applying and releasing the underdrive brake (B3) piston with 60 psi of air pressure to determine appropriate backing plate thickness as shown in Figure 192. Final Assembly Continued on Page 99.

UNDERDRIVE BRAKE (B3) LINED PLATES (3 REQUIRED)

UNDERDRIVE BRAKE (B3) RETAINING SNAP RING

UNDERDRIVE BRAKE (B3) BACKING PLATE


Figure 191 SELECTIVE BACKING PLATES AVAILABLE FROM THE DEALER. ORDER BY THICKNESS.

MAKE CERTAIN THE SNAP RING IS FULLY SEATED IN SNAP RING GROOVE.

UNDERDRIVE BRAKE (B3) STEEL PLATES (3 REQUIRED)

Un derdr ive Br ake (B3) Clu tch Cl earan ce/Piston Tr avel 1.87 - 2.08mm (.074 - .081”) Selective Un der dri ve Br ake Backing Pl ates 3.0 mm (.118”) 3.4 mm (.134”) 3.2 mm (.126”) Copyr ight © 2009 ATSG

Figure 190

98


Figure 192


Technical Service Information FINALASSEMBLY I nter nal components 94. Attach the anti-rattle clip to the No. 2 one way clutch (F2) as shown in Figure 193. 95. Coat the rollers of the No. 2 one way clutch (F2) with a small amount of ATF, then install into the case with the anti-rattle clip in the 6 o-clock position in the case and the directional marks facing upward as shown in Figure 193. 96. Using a small screwdriver, install the no. 2 one way clutch (F2) retaining snap ring into the case as shown in Figure 193. 97. Make certain the retaining snap ring is fully seated in the snap ring groove in the case as shown in Figure 194. 98. Make certain the anti-rattle clip does not become detached upon installation. 99. Coat the underdrive clutch (C3) thrust bearing race with a small amount of Trans-Jel® and install it onto the ring tower in the case as shown in Figure 195. 100.Coat the underdrive clutch (C3) thrust bearing and race assembly with a small amount of Trans-Jel® and install into the underdrive clutch

MAKE CERTAIN RETAINING SNAP RING IS FULLY SEATED IN THE SNAP RING GROOVE


Figure 194

UNDERDRIVE CLUTCH (C3) THRUST BEARING RACE

Final Assembly Continued on Page 100. DIRECTIONAL MARKS NO. 2 ONE WAY CLUTCH (F2) RETAINING SNAP RING ANTI-RATTLE CLIP

NO. 2 ONE WAY CLUTCH (F2)


Figure 195

UNDERDRIVE CLUTCH (C3) THRUST BEARING AND RACE ASSEMBLY

UNDERDRIVE CLUTCH (C3) DRUM ASSEMBLY



Figure 193

Figure 196


99

Technical Service Information FINALASSEMBLY I ntern al components 101.Install the underdrive clutch (C3) drum into the case by turning in a counter-clockwise direction so that the hub on the drum fully splines into the underdrive brake (B3) lined plates in the case as shown in Figure 197. 102.Check for proper one way clutch operation. The underdrive clutch (C3) drum must rotate in a counter-clockwise direction and locks clockwise as shown in Figure 198.

103.Clip the park pawl return spring onto the park pawl and slide the park pawl into the case as shown in Figure 199. 104.Install the park pawl return spring retaining pin as shown in Figure 200. Final Assembly Continued on Page 101.

PARK PAWL

INSTALL DRUM BY TURNING COUNTER-CLOCKWISE SO THE HUB SPLINES INTO THE LINED PLATES IN THE CASE UNDERDRIVE CLUTCH (C3) DRUM ASSEMBLY

PARK PAWL RETURN SPRING


Figure 197 UNDERDRIVECLUTCH(C3) DRUM MUSTROTATECOUNTER-CLOCKWISE ANDLOCKCLOCKWISE


Figure 199 PARK PAWL RETURN SPRING RETAINING PIN


Figure 198

100


Figure 200


Technical Service Information FINALASSEMBLY I nter nal components 105. Position the park pawl in the case as shown in Figure 201 to provide for proper installation of the underdrive planetary assembly. 106. Install the underdrive planetary assembly into the case using a twisting motion so that the clutch hub splines into the underdrive lined plates and the planetary gears mesh with the sun gear on the underdrive clutch drum as shown in Figure 201. 107. Slide park pawl into position then install the park pawl shaft into the case and through the park pawl as shown in Figure 202. 108. Install the park pawl shaft hold down bracket into position in the case as shown in Figure 202. 109. Install the park pawl shaft hold down bracket retaining bolt and thread into the case as shown in Figure 203. 110. Torquetheparkpawl shaft holddownbracket

PARK PAWL SHAFT

PARK PAWL SHAFT HOLD DOWN BRACKET

retainingbolt to9.8 Nm(7ft. lb.) Final Assembly Continued on Page 102.


Figure 202 PARK PAWL SHAFT HOLD DOWN BRACKET RETAINING BOLT

UNDERDRIVE PLANETARY ASSEMBLY

TORQUEBOLTTO 9.8 Nm(7ft. lb.)

PARK PAWLMUST BEPOSITIONEDAS SHOWNFORUNDERDRIVE PLANETARYASSEMBLY TOBEINSTALLED


Figure 201


Figure 203


101

Technical Service Information FINALASSEMBLY I nter nal components 111. Using a straight edge across the top of of the drive pinion gear, take a measurement from the top of the straight edge to the contact area of the torque converter housing. Deduct the height of the straight edge from the overall height to obtain (”Dimension C”) as shown in Figure 204. 112. Next, measure the distance from the base of the torque converter housing to the area where the housing contacts the transaxle case as shown in Figure 205. This is (“Dimension 3”). 113. Now, take a measurement from the base of the torque converter housing to the top of the bearing seat as shown in Figure 205. This is (“Dimension 4”). Deduct (”Dimension 4” from (”Dimension 3”) to determine “Dimension D”. Next, deduct “Dimension D”, the underdrive planetary thrust bearing thickness 3.28 mm and the thickness of the underdrive (.129 in .) planetary thrust bearing race from “Dimension C” so the end play is .198 - .693 mm (.0078 .0273 in .).

114. Select the appropriate underdrive planetary thrust bearing race from the chart shown in Figure 206 to obtain proper end play measurement. Final Assembly Continued on Page 103. OBTAINING“DIMENSIOND” “Dimension D” is obtained by measuring from the base of the differential housing to the area where the torque converter housing contacts the transaxle case (“Dimension 3”) and then measuring from the top of the bearing seat to the area where the torque converter housing contacts the transaxle case (“Dimension 4”). Deduct (“Dimension 4”) from (“Dimension 3”) to determine “Dimension “B”. DIM EN SIO N 3

D IM ENS IO N 4


Figure 205 OBTAINING“DIMENSIONC” “Dimension C” is obtained by measuring from the top of the straight edge to the differential housing and deducting the height of the straight edge from the total measurement.


SELECTIVE RACE AVAILABLE FROM THE DEALER. ORDER BY THICKNESS.

0 1 .2 4 5

I N

END PLAY 0.198 - 0.693 mm (.0078 - .0273 in.) THICKNESS

I NSI DE DI A.

3.5 mm (.138”)

57.2 mm (2.252”)

84.96 mm (3.3449)

3.8 mm (.150”)

57.2 mm (2.252”)

84.96 mm (3.3449)


Figure 204

102

OUTSI DE DI A.


Figure 206


Technical Service Information FINALASSEMBLY I ntern al components 115. Coat the forward (C1) clutch hub thrust bearing race with a small amount of Trans-Jel® and install the race onto the transfer drive gear as shown Figure 207. 116. Coat the forward (C1) clutch hub thrust bearing with a small amount of Trans-Jel® and install the thrust bearing onto the splined side of the forward clutch hub as shown in Figure 208. 117. Install the forward (C1) clutch hub into the transmission while turning to engage the splines as shown in Figure 208. 118. Coat the forward (C1) clutch thrust bearing with a small amount of Trans-Jel® and install into the forward clutch hub with the lip facing down into the hub as shown in Figure 208. 119. Install the forward (C1) clutch drum assembly with a twisting motion so the lined plates spline with the hub as shown in Figure 209.

FORWARD (C1) CLUTCH HUB THRUST BEARING RACE


Figure 207


FORWARD (C1) CLUTCH THRUST BEARING

FORWARD (C1) CLUTCH HUB

FORWARD (C1) CLUTCH HUB THRUST BEARING SPLINED SIDE



Figure 208

Figure 209


103

Technical Service Information FINALASSEMBLY I ntern al components 120. Coat the underdrive planetary thrust bearing race with a small amount of Trans-Jel® and install the race onto the underdrive planetary assembly drive pinion gear in the case as shown in Figure 210. 121. Coat the underdrive planetary assembly thrust bearing with a small amount of Trans-Jel® and install onto the race in the case as shown in Figure 210. 122. Coat the two lube seals with a small amount of Trans-Jel® and install them into the case in the locations shown in Figure 211. 123. Install the oil pump assembly onto the case and install the seven oil pump retaining bolts as shown in Figure 212.

LUBE SEALS (2 REQUIRED)



Figure 211

5 UNDERDRIVE PLANET ASSEMBLY THRUST BEARING

6


5. OIL PUMP ASSEMBLY 6. OIL PUMP RETAINING BOLTS (7 REQUIRED)



Figure 210

104

Figure 212


Technical Service Information FINALASSEMBLY I nter nal components 124. Tighten the seven pump retaining bolts and torque all pump bolts to 22 N m (16 ft. lb.) . 125. Re-coat the differential tapered roller bearings with a small amount of ATF if necessary and install the differential carrier into the case as shown in Figure 214. 126. Apply a thin bead of FIPG Part No. 0882600090, THREE BOND 1281 or equivalent anaerobic sealant to the transaxle case. 127. Install the converter housing to the transaxle case as shown in Figure 215. 128. Apply a small amount of THREE BOND 2403 or equivalent anaerobic sealant to the bolts marked “C” shown in Figure 215. 129. Note the bolt lengths and torque specifications as shown in the chart in Figure 215 and torque all converter housing bolts as specified.


Figure 214


B

A

TORQUEALLPUMP BOLTSTO 22Nm (16 ft. lb.)

A

C

BOLT

LENGTH

TORQUE

BOLTA: (7REQUIRED) BOLTB: (4 REQUIRED) BOLTC: (5REQUIRED)

42 mm(1.654 in.) 50mm(1.969in.) 50mm(1.969in.)

29Nm(22ft. lb.) 29Nm(22ft. lb.) 22Nm(16 ft. lb.)


Figure 213


Figure 215


105

Technical Service Information FINALASSEMBLY I nter nal components 130.Check the input shaft end play using a dial indicator and move the input shaft in an up/down manner as shown in Figure 213. 131.Install new o-rings on the C1, C3, and B3 accumulator pistons as shown in Figure 214. 132.Coat each of the o-rings with a small amount of ATF or Trans-Jel®. Note: Spr in g color s and dim ension s have been pr ovided in F igu re 214, however, ther e may be vari ations fr om model to model. 133.Install the C1 accumulator spring into the c ase using the identifier chart shown in Figure 214. 134.Install the C1 accumulator piston into the c ase as shown in Figure 214. 135.Install the C3 accumulator piston into the c ase as shown in Figure 214. 136.Install the C3 accumulator spring into the c ase using the identifier chart shown in Figure 214.

137.Install the B3 accumulator inner and outer springs into the case using the identifier chart shown in Figure 214. 138.Install the B3 accumulator piston into the c ase as shown in Figure 214. Final Assembly Continued on Page 107. C1 ACCUMULATOR LINE UP

C3 ACCUMULATOR LINE UP

B3 ACCUMULATOR LINE UP

O-RING

O-RING

O-RING

CHECKING INPUTSHAFTENDPLAY NOTE: THEREARENOSELECTIVEPARTS FORENDPLAY. IFENDPLAY ISNOTWITHINSPECIFICATION, THEREISEITHERAMIS-ASSEMBLY ERROR, ORWORNPARTS.

I nput Shaft En d Play .27 - 1.24 mm ( .0106 - .0417 in .)

O-RING

ACCUMULATOR SPRING

OUTSIDE DIAMETER

C1

18.5 mm (.728 in.)

90.53 mm (3.564 in.)

RED

C3

19.2 mm (.756 in.)

86.66 mm (3.411 in.)

WHITE

B3 INNER

15.9 mm (.626 in.)

60.24 mm (2.371 in.)

GREEN

B3 OUTER

16.7 mm (.657 in.)

72.61 mm (2.858 in.)

BLUE

106

ID COLOR



Figure 213

FREE LENGTH

Figure 214


Technical Service Information FINALASSEMBLY I nter nal components 139.Coat the inside lip of the manual lever shaft seal with a small amount of ATF or Trans-Jel® and install into the case by lightly tapping with a small hammer as shown in Figure 215. 140.Install the park actuator rod into the manual valve detent lever as shown in Figure 216. 141.Install the manual lever shaft into the trans with a twisting motion, using care to not damage the seal and push it through the manual valve detent lever as shown in Figure 216. 142.Install the spacer sleeve into the case over the manual lever shaft as shown in Figure 217. 143.Align the hole in the manual valve detent lever with the hole in the manual lever shaft and install the roll pin into the detent lever using a small hammer as shown in Figure 217. 144.Slide the spacer sleeve over the detent lever so it covers the roll pin as shown in Figure 218. 145.Install the manual shaft locating pin as shown in Figure 218.

146.Install the manual lever detent spring tensioner plate and the manual lever detent spring as shown in Figure 219. 147.Install the retaining bolt into the detent spring and tensioner plate (finger tight only). 148.Install the park pawl lock bracket and the bolts finger tight only as shown in Figure 219. 149. Now torque all bolts as specified in Figure 219. Final Assembly Continued on Page 108. SPACER SLEEVE

ROLL PIN


Figure 217 MANUAL SHAFT LOCATING PIN

SPACER SLEEVE

Copyr ight © 2009 ATSG Copyr ight © 2009 ATSG

Figure 215 MANUAL VALVE DETENT LEVER

MANUAL LEVER SHAFT

Figure 218 MANUAL LEVER DETENT SPRING TENSIONER PLATE

MANUAL LEVER DETENT SPRING PARK ACTUATOR ROD

BOLT 12 N m (9 ft. lb.)

INSTALL SHAFT INTO THE CASE IN THE DIRECTION OF THE ARROW.

BOLTS PARK PAWL LOCK BRACKET


Figure 216

20 N m (15 ft. lb.)


Figure 219


107

Technical Service Information FINALASSEMBLY I nter nal components 150.Install the B1 brake tube seal into the case as shown in Figure 220 151.Coat the valvebody to case seal B1 with a small amount of Trans-Jel® and install into the case as shown in Figure 220. 152.Coat the valvebody to case seal B2 with a small amount of Trans-Jel® and install into the case as shown in Figure 220. 153.Install the anti-drain back check valve into the case with the ball facing upward as shown in Figure 220.


B1 BRAKE TUBE SEAL

154.Install a new o-ring onto the internal harness case connector and coat the o-ring with a small amount of Trans-Jel® as shown in Figure 221. 155.Install a new o-ring onto the ATF temperature sensor as shown in Figure 221. 156.Install the internal harness case connector into the case with a twisting motion, then install and torque the retaining bolt as shown in Figure 221. Torque bolt to 5.4 N m (48 i n. l b.) Final Assembly Continued on Page 109.

VALVEBODY TO CASE SEAL B2 INTERNAL HARNESS CASE CONNECTOR

O-RING

TORQUEBOLTTO 5.4 Nm(48 in. lb.)

ANTI-DRAIN BACK CHECK VALVE O-RING



Figure 220

108

Figure 221


Technical Service Information FINALASSEMBLY I nter nal components 157.Install the valve body onto the case as shown in Figure 222 using care to not pinch the wires of the internal harness. 158.Make sure to align the manual valve so the pin on the detent lever is between the grooves at the end of the manual valve as shown in Figure 222. 159.Install the seventeen valve body to case attaching bolts according to proper length as shown in Figure 222. 160.Tighten the two locating bolts marked with the asterisk finger tight first, then the remaining ones. 161.Torque the valve body attachin g bolts to; 11 N m (8 f t. lb.) Final Assembly Continued on Page 110.

BOLT LENGTH

BOLT A: 25 mm (0.984” in.) BOLT B: 41 mm (1.614” in.) BOLT C: 45 mm (1.771” in.) INDICATES LOCATING BOLT

*

TORQUEALL VALVEBODY ATTACHINGBOLTSTO 11Nm(8 ft. lb.)

A

C

* B A C

C

* B

B


Figure 222


109

Technical Service Information FINALASSEMBLY I nter nal components 162.Connect all solenoid connectors according to the diagram in Figure 223. 163.Make certain the connectors are plugged in all the way until the locking tabs snap into place. 164.Coat the ATF temperature sensor o-ring with a small amount of Trans-Jel® then install into the locating hole in the valve body. 165.Install the ATF temperature sensor hold down bracket and the attaching bolt as shown in Figure 223. 166.Torque the bolt to 6.6 N m (58 in . lb.) Final Assembly Continued on Page 111.

TORQUEBOLTTO 6.6 Nm(58 in. lb.)

SHIFT SOLENOID VALVE S4 “SOLENOID D” (BLACK CONNECTOR SINGLE RED WIRE)

ATF TEMPERATURE SENSOR HOLD DOWN BOLT AND BRACKET

SHIFT SOLENOID VALVE SL2 “SOLENOID B” (CLEAR CONNECTOR BROWN AND YELLOW WIRES)

SHIFT SOLENOID VALVE DSL “LOCKUP SOLENOID” (REDDISH BROWN CONNECTOR SINGLE GREEN WIRE)

ATF TEMPERATURE SENSOR (TWO ORANGE WIRES)

SHIFT SOLENOID VALVE SL1 “SHIFT SOLENOID A” (CLEAR CONNECTOR BLACK AND WHITE WIRES)

SOLENOID VALVE SLT “LINE PRESSURE SOLENOID” (CLEAR CONNECTOR GREEN AND ORANGE WIRES)


Figure 223

110


Technical Service Information FINALASSEMBLY I nter nal components 167.Install a new oil filter gasket onto the oil filter using a small amount of Trans-Jel® as shown in Figure 224. 168.Install the oil filter and gasket onto the valve body then install the three oil filter attaching bolts as shown in Figure 224. 169.Torque the fi lter bol ts to 11 N m ( 8 ft. l b.) 170.Install a new oil pan gasket onto the case as shown in Figure 225. 171.Coat the eighteen oil pan attaching bolts with a small amount of THREE BOND 2430 or equivalent anaerobic sealant and install them as shown in Figure 225. 172.Torque all pan bolts to 7.8 N m ( 69 in. l b.)

TORQUEOILPAN ATTACHINGBOLTSTO 7.8 Nm(69in. lb.)

OIL PAN


TORQUEOILFILTER ATTACHINGBOLTSTO 11Nm(8 ft. lb.)

OIL PAN GASKET

OIL FILTER

FILTER BOLT (3 REQUIRED)

PAN BOLT (18 REQUIRED)

FILTER GASKET


Figure 224


Figure 225


111

Technical Service Information FINALASSEMBLY I nter nal components 173.Install a new o-ring on the NT tubine speed sensor and coat the o-ring with a small amount of Trans-Jel®. 174.Install sensor into case and torque retaining bolt to 11 N m (8 f t. lb.) as shown in Figure 226. 175.Install a new o-ring on the NC counter gear speed sensor and coat the o-ring with a small amount of Trans-Jel®. 176.Install sensor into case and torque retaining bolt to 11 N m (8 ft . lb) as shown in Figure 226. 177.Install a new o-ring on the vehicle speed sensor (if equipped) and coat o-ring with a small amount of Trans-Jel® 178.Install sensor into case and torque retaining bolt to 11 N m (8f t. lb.)

179.Install the park/neutral position switch onto the transaxle and align the holes in the switch with the threads in the case. 180.Align the park/neutral switch as shown back in Figure 8 and install the park/neutral switch retaining bolts and torque the retaining bolts to 5.4 N m (48 in . lb.) as shown in Figure 226. 181.Install the locking washer and the retaining nut. 182.Torque the nut to 6.9 N m (61 in. l b.) then bend the tabs on the locking washer into place over the retaining nut. 183.Install the control shaft lever, the lock washer and the retaining nut and torque the retaining nut to 6.9 N m (61 in . lb.) as shown in Figure 226. Final Assembly Continued on Page 113.

TORQUE 11Nm(8 ft. lb.)

TORQUE 11Nm(8 ft. lb.)

RETAINING BOLT

RETAINING BOLT

TORQUE 11Nm(8 ft. lb.) RETAINING BOLT

(VSS) VEHICLE SPEED SENSOR (SOME MODELS)

(NT) TURBINE SPEED SENSOR

(NC) COUNTER GEAR SPEED SENSOR

O-RING

O-RING O-RING

6.9Nm(61in. lb.) RETAINING NUT AND LOCK WASHER

TORQUE 5.4Nm(48 in. lb.) RETAINING BOLT

6.9Nm(61in. lb.) RETAINING NUT

CONTROL SHAFT LEVER

RETAINING BOLT

LOCKING WASHER

PARK/NEUTRAL POSITION SWITCH (TRANSMISSION RANGE SENSOR)


Figure 226

112


Technical Service Information FINALASSEMBLY I nter nal components 184.Install the torque converter into the transaxle so it is fully engaged into the pump gears and splines as shown in Figure 227. Final Assembly Complete.


Figure 227

TORQUESPECIFICATIONS Internal harness connector to case................................................................... 5.4 Nm (48 in. lb.) ATF temp sensor hold down bracket................................................................. 6.6 Nm (58 in. lb.) NC counter gear speed sensor to case............................................................. 11 Nm (8 ft. lb.) NT turbine speed sensor to case........................................................................11 Nm (8 ft. lb.) Park/neutral switch to case (2 required)............................................................5.4 Nm (48 in. lb.) Park/neutral switch retaining nut....................................................................... 6.9 Nm (61 in. lb.) Control shaft lever to control shaft..................................................................... 6.9 Nm (61 in. lb.) Oil pan drain plug............................................................................................... 17 Nm (13 ft. lb.) Oil pan to case (18 required)............................................................................ 7.8 Nm (69 in. lb.) Oil filter to valvebody (3 required)..................................................................... 11 Nm (8 ft. lb.) Valvebody to case (17 required)....................................................................... 11 Nm (8 ft. lb.) Valvebody attaching A (3 required).................................................................... 11 Nm (8 ft. lb.) Valvebody attaching B (3 required).................................................................... 6.6 Nm (58 in. lb.) Valvebody attaching C (7 required)....................................................................11 Nm (8 ft. lb.) Valvebody attaching D (7 required)....................................................................11 Nm (8 ft. lb.) Valvebody attaching E (1 required).................................................................... 11 Nm (8 ft. lb.) Valvebody attaching F (6 required).................................................................... 6.6 Nm (58 in. lb.) Valvebody attaching G (1 required)....................................................................6.6 Nm (58 in. lb.) Park pawl bracket to case (3 required)............................................................. 20 Nm (15 ft. lb.) Park pawl shaft clamp to case........................................................................... 9.8 Nm (87 in. lb.) Manual lever detent spring to case.....................................................................12 Nm (9 ft. lb.) Transaxle rear cover to case A (1 required)........................................................18.6 Nm (14 ft. lb.) Transaxle rear cover to case B (10 required) .....................................................24.5 Nm (18 ft. lb.) Feed tube hold down bracket to case................................................................5.4 Nm (48 in. lb.) Converter housing to transaxle case A,B (11 required)....................................29 Nm (21 ft. lb.) Converter housing to transaxle case C (5 required)..........................................22 Nm (16 ft. lb.) Oil pump to case (7 required)............................................................................ 22 Nm (16 ft. lb.) Pump cover to pump body (11 required)............................................................9.8 Nm (87 in. lb.) UD planetary locking nut................................................................................... 280 Nm (207 ft. lb.) Counter drive gear locking nut...........................................................................280 Nm (207 ft. lb.)


Figure 228


113

Technical Service Information CASE PASSAGE I .D. AI R TEST PORTS

Torqu e Converter Apply x

C3 Apply

Pini on Shaft lube B3 Apply

B1 Apply

B2 Apply x

Pump Suction

C2 Apply Pump Output

Rear L ube

x

Central lube (not all models)

Torque Converter Of f x x

C1 Apply

F rom Cooler (to sump) To Cooler C1 Accumul ator B3 Accumul ator C3 Accumulator Accumulator Back Pressur e


Figure 229

114


Technical Service Information LINEPRESSURETAP LOCATIONSANDSPECIFICATIONS

UD CLUTCH (C3)

MAIN LINE PRESSURE

DIRECT (C2) CLUTCH

LUBE

LINE PR ESSURE SPECIF ICATIONS RAN G E

ID LE

STALL

D

54-65psi. 93-116psi.

131-160psi. 251-294psi.

R

FLUIDLEVELCHECKINGANDATFCAPACITY/REQUIREMENT Check fluid with temperature between 70 - 80 °C (158 - 176 °F) selector lever in park position with parking brake set. Fluid level should be between the hot marks on the stick. Dry Fill...............................8.6 liters Drain and Re-fill.................3.3 liters

t o h

l o o c

Fluid requirement: Toyota ATF Type T-IV Part Number 08886-81015 Copyr ight © 2009 ATSG

Figure 230


115

Technical Service Information

ECMMEMORYRESETPROCEDURE ECM RESET M EM ORY FU NCTI ON Whenever the U-140E/F or U-240E automatic transmission is replaced, overhauled or individual components are replaced, use this procedure to clear Engine Control Module ECM/PCM “Learned Values” to minimize subsequent performance issues, or possible damage to transaxle. Use the memory reset procedure listed in Figure 231 below, using the required SSTs. CAUTION: F ail ur e to fol low the procedur e below may lengthen the time to readju st the ECM /PCM “L earn ed Valu es” potenti all y resul tin g in performan ce concerns, or tr ansaxle damage. REQUIRED (SSTs) SPECIAL SERVICE TOOLS (SSTs)

PART NUMBER

QUANTITY

Toyota Diagnostic Tester Kit*

01001271

1

CAN Inter face Module Kit*

01002744

1

01002593-005

1

12 Megabyte Diagnostic Tester Pr ogr am Car d with ver sion 12.01a (or later ) Software* * Essential SSTs.

NOTE: Additional Diagnostic Tester Kits, CAN interface Modules, Program Cards or other SSTs may be ordered by calling SPX/OTC at 1-800-933-8335.

A

B

*APPLICATION SELECT*

FUNCTION SELECT FOR NORTH AMERICA 1: OBD/MOBD 2: ENHANCED OBD II 3. CARB OBD II 4: BREAK-OUT BOX 5. NVH 6: AUTOPROBE 7: O2 RPM CHECK 8: SNAPSHOT REVIEW 9: SETUP 10: GAS ANALYSIS

1: DIAGNOSIS 2: CUSTOMIZE 3: ECU REPROGRAM

D RESET MEMORY NOTICE DO NOT USE THIS FUNCTION UNLESS INSTRUCTED BY REPAIR MANUAL. USE ONLY AFTER REPLACING THE ENGINE, AUTO TRANS, OR ECM ON CERTAIN VEHICLES..

C DIAGNOSTIC MENU ENGINE 1: DATA LIST 2: DTC INFO 3: ACTIVE TEST 4: SNAPSHOT 5: SYSTEM CHECK 6: RESET MEMORY 7: MONITOR STATUS 8: CHECK MODE

E

F

RESET MEMORY

RESET MEMORY

EXECUTING THIS FUNCTION WILL RESET THE LEARNED VALUES IN THE ECM. DO YOU WISH TO RESET THE ECM? (YES) to CONTINUIE (NO) to EXIT

RESETTING COMPLETE

PRESS (ENTER)

Figure 231

116



Technical Service Information (SST) SPECIALSERVICETOOLS

(09316-000100) Driver Handle

(09351-32070) Spring Compressor

(09351-32090) Seal Remover/Installer Tool

(09351-32120) Bearing Driver

(09351-32140) Seal Installer

(09351-32150) Seal Installer

09387-00020 Spring Compressor

09387-00030 Counter Drive Gear Holding Tool

09387-00040 Bearing Puller Assembly

(09387-01010) Bearing Puller Adapter


(09387-01030) Bearing Puller Adapter Pins

(09387-01040) Bearing Puller Body



Figure 232


117



09387-00080 Counter Drive Gear Socket

09506-35010 Bearing Driver

09514-35011 Bearing Puller

09564-16020 Socket/Wrench

09564-32011 Differential Preload Adapter

09649-17010 Bearing Driver

09930-00010 Chisel

(09931-00010) Handle

(09931-00020) Chisel

09950-00020 Bearing Remover

09950-00030 Bearing Remover Attachment

09950-40011 Bearing Puller Set

(09951-04010) Sliding Arm Hanger Copyr ight © 2009 ATSG

Figure 233

118



(09952-04010) Sliding Arm

(09953-04020) Center Bolt

(09953-04030) Center Bolt

(09954-04010) Arm



(09958-04011) Holding Fixture

09950-70010 Handle Set

09951-07100 Handle

09951-07150 Handle

09950-60010 Driver Set

09950-60020 Driver Set

(09951-00230) Driver

(09951-00250) Driver Copyr ight © 2009 ATSG

Figure 234


119

U140

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