torque converter & transmission

2-1

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TORQUE CONVERTER & TRANSMISSIONPage

1 SPEED TORQUE CONVERTER (STD) ..............2-2GENERAL ................................2-2HYDRAULIC CIRCUIT

DIAGRAM ..............................2-5SPECIFICATIONS .....................2-6COMPONENTS.........................2-7TROUBLESHOOTING .............2-16TRANSMISSION COVER &

CONTROL VALVE ASSY........2-17TORQUE CONVERTER·

OIL PUMP ............................2-21TORQUE CONVERTER &

TRANSMISSION ASSY..........2-24TRANSMISSION ASSY............2-28CLUTCH DRUM ASSY.............2-35

2 STATORS TORQUE CONVERTER (OPT)............2-39GENERAL..............................2-39HYDRAULIC CIRCUIT

DIAGRAM ............................2-41SPECIFICATIONS...................2-42COMPONENTS.......................2-43TROUBLESHOOTING .............2-47TORQUE CONVERTER ...........2-48TORQUE CONVERTER &

TRANSMISSION ASSY..........2-54TRANSMISSION ASSY............2-58STATOR SHAFT NO.2 &

OIL PUMP ASSY...................2-69CLUTCH DRUM ASSY ............2-71

DIRECTION SWITCH ASSY ...................................2-74REMOVAL·INSTALLATION ......2-74

OIL PRESSURE MEASUREMENT AND STALL TEST (1 SPEED TORQUE CONVERTER (STD))...........2-75

OIL PRESSURE MEASUREMENT AND STALL TEST (2 STATORS TORQUE CONVERTER (OPT))...........2-77

kalstatt

Text Box

8FG(D)U15-32, 8FGCU20-32

2-22-2

1 SPEED TORQUE CONVERTER (STD)

GENERAL

Torque Converter

F: ForwardR: Reverse

R F

Transmission Pn & Cu2~3 ton series

Section 2

2-3

0123456789101112131415161718192021E

Control Valve (Upper)

A A

B B

C C

A-A: Regulator valve

B-B: Inching valve

C-C: Accumulator


Section 2

2-42-4

Control Valve (Lower)

A A

B

C

B

C

A-A: Safety valve

B-B: Shift change valve (R)

C-C: Shift change valve (F)


Section 2

2-5

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HYDRAULIC CIRCUIT DIAGRAM

In-li

ne s

train

er

Rel

ief

valv

e

Coo

ler

Oil

filte

r

R c

lutc

h

F cl

utch

Reg

ulat

or v

alve

Acc

umul

ator

Inch

ing

valv

e

Shift

cha

nge

valv

e (F

)

Shift

cha

nge

valv

e (R

)

Saf

ety

valv

e

Sole

noid

val

ve (R

)

Sole

noid

va

lve

(F)

Oil

pum

p


Section 2

2-62-6

SPECIFICATIONS

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

Torque Converter Ratio

Item 1 speed torque converter

Maker Aisin

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

Torque converter model AISIN

Stall torque ratio 2.68

Stall speed rpm 2200

Control system Solenoid type selector valve

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

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

Torque converter oil capacity l (USgal) 8.0 (2.11)

Torque converter oil ATF GM Dexron® II

Vehicle model EngineTorque Converter Ratio

Forward Reverse

Pn1·2·3 ton series and Cu2·3 ton series 4Y·1DZ-II 1.633 1.641

Pn2·3 ton series and Cu2·3 ton series 4Y (High Power Spec.) 1.323 1.341


Section 2

2-7

COMPONENTS

Torque Converter Housing (4Y Engine Vehicle, Dry Brake Model (STD))

Torque Converter Housing (1DZ-II Engine Vehicle, Dry Brake Model (STD))

3201

3201

3201-238

BV46

BUBP

36

01CT

AR

JO

DR

42

CW

AS

DJ

3201-236

BV46BUBP

36

01CT

ARJO

DR

DR

42

ES

AS

DJCW


Section 2

2-82-8

Torque Converter Housing (4Y Engine Vehicle, Wet Brake Model (OPT))

Torque Converter Housing (1DZ-II Engine Vehicle, Wet Brake Model (OPT))

3201

3201

3201-239

BV46BUBP

36

01

CT

AR

DR

42

DJ

3201-237

BV46BUBP

36

01CT

AR

DR

DR42

ES

DJ


Section 2

2-9

T

Torque Converter

3201

3202

3201-228A

CC

22

GN

AE

41

30JT

CH

JSDP

25

ET

EU

BN

ESBP

BH

AO

DU

25A

3202-099

AM

30

AA

11

22

23

24

AZ

BQ

01


Section 2

2-102-10

4Y Engine Vehicle

1DZ-II Engine Vehicle

3202

3202

3202-100

ARAS

AH

AL

AL

AYAL

AL

AL

20

3202-101

AR

AS

AH

AL

20

AL

AL

ATAL

AL


Section 2

2-11

Torque Converter Clutch

Torque Converter Gear

3203

3204

3203-140

20

43

AJ

AO50

41

40

51

51A45

AT

24D

43

AJ

AO50

51A

51

40

41

45D

10

BS

24B

24

24A

22B

22

22A

46

11

23B

23

23A 21

46B

CP

24E

45A

46A

3204-085

Refer toFIG.3203

45

AD

AP

45A

75B

45B

BA

41

41A

42A

AZ42

46


Section 2

2-122-12

Control Valve

3206

3206

3206-130

GJ

GH

JE

FV

32

DC

32

DC

DC

BC

DD

01

16

JQ

CO

JH

JD

GD

JQ

PF

EX

LQ

SE

GI

10

EX

PF

CB

CB

CB

GA

CB

HR

JQ

JQCB

3206-128

ATDY

BGDF

50

AT

BX

BGHF

44

DW

54

AT

CJ

BG

51

HV

HH

10

KB

BG

CC

PDAF

AK

AD AB

AL


Section 2

2-13

T

Torque Converter Piping (Dry Brake Model (STD))

3206

3213

3206-129

GK

61

AY

AG

LH

AY

60

AY

AG

LH

LH

AG

60

16

HR

3213-158

FN

FN

GY

BA

BA

42

41

BA

AG

AC AO

BA

AGBP


Section 2

2-142-14

Torque Converter Piping (Wet Brake Model (OPT))

3213

3213

3213-159

GY

BA

BA

42

41

FN

FN

AG

AC

AO

HQ BA

BA

AGBP

HQ

3213-155

10

GL

30

JG


Section 2

2-15

Direction Switch

5701

5701-511A

SH

LD

AT

KA

LG

97SJ NT

AI

14

LG

KA

SHAI

LG

QB

A2


Section 2

2-162-16

TROUBLESHOOTINGO

n-b

oard

inspection

Dis

assem

bly

and inspection

Com

ponents

oth

er

than c

ontr

ol valv

es

(torq

ue c

onvert

er

& tra

nsm

issio

n)

Co

ntr

ol va

lve

Faulty s

tart

ing

No s

tart

ing a

t F

No s

tart

ing a

t R

No s

tart

ing a

t any r

anges

Regulator valve

Inching valve

Shift change valve for F

Shift change valve for R

Safety valve

Accumulator for F, R

Solenoid valve for F

Solenoid valve for R

In-line strainer

Oil strainer

Torque converter

Oil pump

Clutch drum for F

Clutch drum for R

Gear, bearing

ATF level and quality

Oil pressure test

Stall test

Shift lever switch and

neutral start switch

Inching lever, and

wire cable

Relief valve

Wire to solenoid

No s

tart

ing a

t N

At sw

itch b

ack

F R

At F

At R

Sta

rter

fails

to r

evolv

e a

t N

.

Sta

rter

rev

olve

at r

ange

s ot

her

than

N.

No

in

ch

ing

op

era

tio

n

Overh

eating o

f tr

ansm

issio

n,

no a

ir flo

w fro

m b

reath

er

Ab

no

rma

l n

ois

e

At N

At R

Larg

e s

hock a

t

sta

rtin

g (

shifting)

Larg

e tim

e lag a

t

sta

rtin

g (

shifting)

Slip

pa

ge

Oth

ers

At N

F

At N

FAt N

R

At N

R

At starting

after shifting

Inching

start


Section 2

2-17

TRANSMISSION COVER & CONTROL VALVE ASSY

REMOVAL·INSTALLATIONT = N·m (kgf·cm) [ft·lbf]

Removal Procedure1 Remove the lower panel.

2 Remove the toe board.

3 Disconnect the inching wire.

4 Disconnect the connector.

5 Remove the transmission cover & control valve ASSY.

Installation ProcedureThe installation procedure is reverse of the removal procedure.

3

4

5

T = 21.0 (214) [15.5]


Section 2

2-182-18

DISASSEMBLY·INSPECTION·REASSEMBLYT = N·m (kgf·cm) [ft·lbf]

Disassembly Procedure1 Disconnect the solenoid valve connector.

2 Remove the solenoid valve.

3 Remove the sleeve lock plate and solenoid wire ASSY.

4 Remove the inching lever.

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

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

7 Remove the lower valve body ASSY, oil strainer, relief valve piston and spring. [Point 3]

8 Remove the safety valve, F shift valve and R shift valve. [Point 4]

Reassembly ProcedureThe reassembly procedure is reverse of the disassembly procedure.

4

54

3

3

7

8

6

T = 21.0 (214) [15.5]

T = 7.9 (81) [5.8]

T = 12.5 (127) [9.2]

T = 7.9 (81) [5.8]

T = 20.2 (206) [14.9]

2

2


Section 2

2-19

Point Operations[Point 1]

Reassembly:

SST 09950-76018-71................................. (1)(09950-60010)09950-76020-71................................. (2)(09950-70010)

[Point 2]

Disassembly:Remove the accumulator valve plug using the service bolt.Service bolt size: M8×1.25

Inspection:Measure free length of each valve spring.

[Point 3]

Reassembly:Install the lower valve body.

1. Install the oil strainer, spring and relief valve piston on thelower valve body, and put the gasket on top.

2. Reverse the above while maintaining the assembled state andinstall it on the transmission cover.

SST(2)

SST(1)

Service bolt

Standard mm (in) Limit mm (in)

Accumulator valveInner 67.4 (3.390) 64.0 (3.220)

Outer 127.8 (5.031) 121.4 (4.780)

Inching valvePlug side 64.2 (2.528) 61.0 (2.402)

Valve side 49.9 (1.965) 47.4 (1.866)

Regulator valve 132.4 (5.213) 125.8 (4.953)


Section 2

2-202-20

[Point 4]

Disassembly:Press in the valve plug with its opening facing downwards andremove the key.



F/R shift valve 59.8 (2.354) 56.8 (2.236)

Safety valve 59.8 (2.354) 56.8 (2.236)


Section 2

2-21

TORQUE CONVERTER·OIL PUMP


Removal Procedure1 Drain torque converter oil.

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

3 Remove the torque converter ASSY. [Point 1]

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

5 Remove the stator shaft. [Point 3]

6 Remove the oil pump drive gear and the oil pump driven gear. [Point 4]

7 Remove the oil seal. [Point 5]



Removal:Be careful as the torque converter ASSY contains oil.

Installation:Apply MP grease to the seal ring and oil seal lip beforeinstallation.

Installation:Install while rotating the torque converter ASSY so that theextension claw engages with the groove in the oil pump drive gear.

3

4

5

T = 21.0 (220) [15.9]

Oil seals


Section 2

2-222-22

[Point 2]

Removal:

SST 09950-76014-71(09950-40011)

Installation:Be careful not to install the pre-coated bolts in incorrectpositions.

Installation:When reusing precoated bolts, apply thread tightener (08833-76002-71 (08833-00080)) to the threaded part.

[Point 3]

Removal:Put match marks on the oil pump and stator shaft ASSY.

Installation:Align match marks when installing.

[Point 4]

Inspection:Measure the clearance between the oil pump driven gear andpump body.

Limit: 0.3 mm (0.012 in)

Inspection:Measure the clearance between the pump body and eachgear.

Standard: 0.042 ~ 0.080 mm (0.002 ~ 0.003 in)

SST

Service tap

Service tap


Section 2

2-23

Inspection:The marks have no meaning for reassembly.

[Point 5]

Installation:

SST 09370-10410-71

Marks

SST


Section 2

2-242-24

TORQUE CONVERTER & TRANSMISSION ASSY


Engine mounting nut T = 53.2 ~ 98.0 (550 ~ 1000) [39.8 ~ 72.3]

Front insulator set bolt T = 68.0 ~ 102.0 (700 ~ 1050) [50.6 ~ 76.0]

Torque converter housing set bolt T = 29.4 ~ 44.1 (300 ~ 450) [21.7 ~ 32.6]

Drive plate set bolt (for connecting to engine crankshaft)

4Y engine vehicleT = 56.8 ~ 64.7 (580 ~ 660) [42.0 ~ 47.8]

1DZ-II engine vehicleT = 76.4 ~ 93.1 (780 ~ 950) [56.4 ~ 68.7]

Drive plate set bolt (for connecting to torque converter) T = 14.7 ~ 21.6 (150 ~ 220) [10.9 ~ 15.9]

29 27

924


Section 2

2-25

Removal Procedure1 Remove the engine hood. (Refer to page 9-9)

2 Remove the lower panel.


4 Drain coolant.

5 Remove the battery.

6 Remove the sedimenter bracket set bolt and leave it free. (1DZ-II engine vehicle)

7 Disconnect the accelerator wire. (1DZ-II engine vehicle)

8 Disconnect the fuel hose.

9 Remove the relay block and leave it free.

10 Remove the battery set plate.

11 Remove the air cleaner and air inlet.

12 Remove the exhaust pipe cover plate.

13 Disconnect the exhaust pipe.

14 Remove the RH side step and side cover.

15 Disconnect the main harness connector inside the RH side cover.

16 Disconnect the oil pump-to-oil control valve hose.


18 Disconnect the torque converter cooler hose (on the transmission side) and drain oil from the torque converter.[Point 1]

19 Disconnect the torque converter cooler hose (on the radiator side). [Point 2]

20 Disconnect the water hose.

21 Remove the radiator and fan shroud.

22 Remove the under cover.

23 Drain the brake cooling oil. (Wet Brake model) (Refer to page 8-62)

24 Remove the brake cooling oil tank. (Wet Brake model) (Refer to page 8-61)

25 Disconnect the wiring and wire harness clamps around the engine and transmission.

26 Remove the oil pump set bolt, and leave it free.

27 Remove the propeller shaft under cover and propeller shaft. (Dry Brake model: Refer to page 3-4, Wet Brake model: Refer to page 3-5)

28 Remove the engine mount nut.

29 Attach the SST to the engine W/ torque converter and transmission ASSY. [Point 3]

30 Remove the front insulator set bolt.

31 Remove the engine W/ torque converter & transmission ASSY. [Point 4]

32 Remove the cover plate.

33 Remove the drive plate set bolts (6 bolts). [Point 5]

34 Disconnect the engine ASSY from the torque converter housing.


Section 2

2-262-26

Installation ProcedureThe installation procedure is the reverse of the removal procedure.

Note:After installing the engine ASSY, perform air bleeding of the fuel system. (1DZ-II engine vehicle) (Refer topage 1-11)


Removal:Put match marks on the transmission case and torqueconverter cooler hose.

[Point 2]

Removal:Put match marks on the radiator and torque converter coolerhose.

[Point 3]

Removal•Installation:

SST 09010-20111-71 ................................. (1)09010-23320-71................................. (2)

[Point 4]

Removal•Installation:Move the SST hook position to adjust the balance.

SST(2)SST(1)

SST


Section 2

2-27

[Point 5]

Removal•Installation:Turn the flywheel using the crankshaft pulley set bolt.

Crankshaft pulley set bolt


Section 2

2-282-28

TRANSMISSION ASSY


T = 56.0(571.0)[41.3]

T = 32 ~ 48(326.3 ~ 489.5)[23.6 ~ 35.4]

T = 49.0 (499.7) [36.2]

T = 19.0 (193.7) [14.0]

T = 21.0 (214.1) [15.5]

T = 69.0 ~ 96.0(703.6 ~ 978.9)[50.9 ~ 70.8]

T = 56.0 (571) [41.3]

T = 12.7 (129.5) [9.4]

4

3

6

12

1513

14

14

1414

10

11

14

7

8

8

9

9

17

16

5


Section 2

2-29

Disassembly Procedure1 Drain torque converter oil.

2 Remove the transmission cover & control valve ASSY.

3 Remove the torque converter.

4 Remove the oil pump W/ stator shaft ASSY and shim. [Point 1]

5 Remove the rear case. [Point 2]

6 Remove the output gear cover, output gear and shim. [Point 3]

7 Remove the counter gear and shim. [Point 4]

8 Remove the counter gear shaft and main shaft ASSY. [Point 5]

9 Remove the spacer, main shaft rear bearing, reverse clutch gear, forward clutch gear, and reverse & forwardclutch drum ASSY. [Point 6](Refer to page 2-35 for disassembly, inspection and reassembly of the clutch drum ASSY)

10 Remove the forward clutch gear bearing. [Point 7]

11 Remove the reverse clutch gear bearing. [Point 8]

12 Remove the output shaft. [Point 9]

13 Remove the output shaft dust deflector. [Point 10]

14 Remove the main shaft front bearing, the counter gear bearing and output gear bearing. [Point 11]

15 Remove the output shaft oil seal. [Point 12]

16 Remove the oil strainer. [Point 13]

17 Remove the oil filter. [Point 14]

Reassembly ProcedureThe reassembly procedure is the reverse of the disassembly procedure.


Disassembly:

SST 09950-76014-71(09950-40011)

Reassembly:Be careful not to install the pre-coated bolts in incorrectpositions.

Reassembly:When reusing precoated bolts, apply thread tightener (08833-76002-71 (08833-00080)) to the threaded part.

SST

Service tap

Service tap


Section 2

2-302-30

Reassembly:Adjust the thrust clearance of the main shaft system.

1. Temporarily assemble the oil pump W/ stator shaft ASSY,shim, and rear case, and measure the thrust clearance of themain shaft gear system.

Standard: A = 0.10 ~ 0.24 mm (0.004 ~ 0.009 in)

2. If the standard is not satisfied, increase or decrease the shimthickness for adjustment.

[Point 2]

Disassembly:Insert a flat head screwdriver in the cut portion of the rear caseand remove the case.

Reassembly:Assemble after removing iron powder staying on the magnet.

A

Shim

Mark Thickness mm (in)

A 1.08 ~ 1.12 (0.043 ~ 0.044)

B 1.18 ~ 1.22 (0.046 ~ 0.048)

C 1.28 ~ 1.32 (0.050 ~ 0.052)

E 1.38 ~ 1.42 (0.054 ~ 0.056)

F 1.48 ~ 1.52 (0.058 ~ 0.060)

G 1.58 ~ 1.62 (0.062 ~ 0.064)

H 1.68 ~ 1.72 (0.066 ~ 0.068)

J 1.78 ~ 1.82 (0.070 ~ 0.072)

K 1.88 ~ 1.92 (0.074 ~ 0.076)

L 1.98 ~ 2.02 (0.078 ~ 0.080)

M 2.08 ~ 2.12 (0.082 ~ 0.083)

N 2.18 ~ 2.22 (0.086 ~ 0.087)

P 2.28 ~ 2.32 (0.090 ~ 0.091)

R 2.38 ~ 2.42 (0.094 ~ 0.095)

S 2.48 ~ 2.52 (0.098 ~ 0.099)

Magnet


Section 2

2-31

[Point 3]

Reassembly:Adjust the output gear thrust clearance.

1. Temporarily install the output gear, shim and rear case, andmeasure the output gear thrust clearance.

Standard: A = 0.10 ~ 0.49 mm (0.004 ~ 0.019 in)


[Point 4]

Reassembly:Adjust the counter gear thrust clearance.

1. Temoporarily assemble the counter gear, shim and rear case,and measure the thrust clearance of the counter gear.

Standard: 0.10 ~ 0.54 mm (0.004 ~ 0.021 in)


[Point 5]

Disassembly•Reassembly:Disassemble or reassemble the counter gear shaft togetherwith the main shaft ASSY.

A

Shim


0 0.375 ~ 0.425 (0.015 ~ 0.017)

2 0.67 ~ 0.75 (0.026 ~ 0.030)

4 0.855 ~ 0.945 (0.034 ~ 0.037)

6 1.065 ~ 1.175 (0.042 ~ 0.046)

7 1.12 ~ 1.24 (0.044 ~ 0.049)

Shim


0 0.375 ~ 0.425 (0.015 ~ 0.017)

2 0.67 ~ 0.75 (0.026 ~ 0.030)

3 0.855 ~ 0.945 (0.034 ~ 0.037)

4 1.01 ~ 1.11 (0.040 ~ 0.044)

5 1.12 ~ 1.24 (0.044 ~ 0.049)

6 1.24 ~ 1.36 (0.049 ~ 0.054)


Section 2

2-322-32

[Point 6]

Inspection:Measure the seal ring side clearance.

Limit: 0.2 mm (0.008 in)

Reassembly:After aligning the clutch disc serration using a screwdriver orthe like, reassemble the clutch gear.

[Point 7]

Disassembly:

SST 09950-76018-71................................. (1)(09950-60010)09950-76020-71................................. (2)(09950-70010)

Reassembly:

SST 09950-76019-71................................. (1)(09950-60020)09950-76020-71................................. (2)(09950-70010)

[Point 8]

Disassembly:

SST 09950-76018-71................................. (1)(09950-60010)09950-76020-71................................. (2)(09950-70010)

SST(2)

SST(1)

SST(2)SST(1)

SST(2)SST(1)


Section 2

2-33

Reassembly:

SST 09950-76019-71................................. (1)(09950-60020)09950-76020-71................................. (2)(09950-70010)

[Point 9]

Disassembly•Reassembly:

SST 09905-76002-71(09905-00012)

[Point 10]

Reassembly:

SST 09370-20270-71

[Point 11]

Disassembly:

SST 09320-23000-71

Reassembly:

SST 09950-76018-71................................. (1)(09950-60010)09950-76020-71................................. (2)(09950-70010)

SST(2)

SST(1)

SST

SST

SST

SST(2)

SST(1)


Section 2

2-342-34

[Point 12]

Disassembly•Reassembly:Use a flat head screwdriver or the like to disassemble orreassemble the output shaft oil seal.

Reassembly:Reassemble the output shaft oil seal to the position A in theillustration.

A = 6.7 ~ 7.7 mm (0.264 ~ 0.303 in)

[Point 13]

Disassembly:Pinch the rib part of the oil strainer with long-nosed pliers, andremove the oil strainer.

[Point 14]


SST 09228-76004-71(09228-07501)

Clutch operation check after reassemblyBlow air through the oil hole on top of the transmission case andcheck that each clutch piston operates normally.

A

SST

RF

RF


Section 2

2-35

CLUTCH DRUM ASSY

DISASSEMBLY·INSPECTION·REASSEMBLY

Disassembly Procedure1 Remove the snap ring.

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

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

4 Remove the clutch piston, piston ring and seal ring. [Point 3]



Inspection:Measure thickness of the clutch disc.

Standard: 2.6 mm (0.102 in)

Limit: 2.3 mm (0.091 in)

1

2

3

4


Section 2

2-362-36

Inspection:Measure thickness of the clutch plate.


Limit: 1.8 mm (0.071 in)

Inspection:Measure height of the camber plate curving.


Limit: 3.1 mm (0.122 in)

Reassembly:Reassemble with the punched side facing upwards (the clutchgear side).

PunchingPiston side

Clutch gear side


Section 2

2-37

Reassembly:Install the clutch plates and clutch discs alternately on theclutch drum while applying torque converter oil.

Number of clutch discs

Reassembly:Adjust the clearance between the backing plate and clutchdisc.

1. Install the camber plate, clutch plates, clutch discs, backingplate and snap ring on the clutch drum.

2. Measure clearance between the backing plate and snap ringusing thickness gauges.

Standard:4-disc specification: 0.8 ~ 1.4 mm (0.031 ~ 0.055 in)5-disc specification: 1.0 ~ 1.6 mm (0.039 ~ 0.063 in)

3. If the measured value is out of the specified range, select asuitable backing plate.

Backing plate thickness

Reassembly:Install the backing plate with its stepped side (with groove)facing upward (on the clutch gear side).

Camber plate

Pn1 ton series 4Y·1DZ-II models 4

Pn2·3 ton series 4Y·1DZ-II models 5

Cu2·3 ton series 4Y model 5

Identifying grooves

A

A Identifying grooves

5.7 mm (0.224 in) 0

6.2 mm (0.244 in) One groove

6.7 mm (0.264 in) Two grooves

Identifying grooves


Section 2

2-382-38

[Point 2]

Disassembly•Reassembly:Compress the return spring using the SST and remove orinstall the snap ring.Tie two hooks of the SST using a wire or string as shown in theillustration to fix it in the clutch drum.

SST 09220-22001-71................................. (1)09905-76002-71................................. (2)(09905-00012)

Caution:The hooks may come off the clutch drum and spring may jumpout when using the SST. Be careful not to allow the hooks tocome off the drum when removing or installing the snap ring.

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


Limit: 58.5 mm (2.303 in)

[Point 3]

Disassembly:Pinch the rib of clutch piston using pliers with cloth in-betweenand remove the piston.

Reassembly:Apply torque converter oil on the piston ring and seal ring, andassemble the clutch piston.

Wire

SST(2)

SST(1)


Section 2

2-39

2 STATORS TORQUE CONVERTER (OPT)

GENERAL

F: ForwardR: Reverse

R

F


Section 2

2-402-40

Control Valve

Inching valve

Regulator valve

Accumulator

A - A

A

A


Section 2

2-41

HYDRAULIC CIRCUIT DIAGRAMM

ain

pre

ssure

port

PT

1/8

"

Forw

ard

pre

ssure

port

PT

1/8

"

Revers

epre

ssure

port

PT

1/8

"

Torq

ue c

onvert

er

Suction filt

er

Forw

ard

clu

tch

Orifice

Oil

filter

Oil

coole

r

Lubrication

Revers

e c

lutc

h

R

R

R N

F

F

FO

N

ON

OF

F

OF

F

OF

FO

FF

Sol (2

)S

ol (1

)

Sol (2

)S

ol (1

)

F/R

sole

noid

valv

e

Coin

filt

er

Inchin

g v

alv

e

Accum

ula

tor

Accum

ula

tor

orifice

Regula

tor

orifice

Main

pre

ssure

Regula

tor

valv

e


Section 2

2-422-42

SPECIFICATIONS

Note:The indicated oil pressure is at an engine speed of 1500 rpm.

Item 2-Stators torque converter

Maker OKAMURA

Torque converter type 4-elements 2-step 3-phases type



Torque converter ratioForward 1.041

Reverse 1.041

Control system Solenoid type selector valve

Clutch operating pressure (main pressure) kPa (kgf/cm2) [psi] 1000 ~ 1400 (10.2 ~ 14.2) [145 ~ 203]

Torque converter outlet pressure kPa (kgf/cm2) [psi] 100 ~ 400 (1.02 ~ 4.1) [14.5 ~ 58]

Torque converter oil capacity l (USgal) 9.0 (2.376)



Section 2

2-43

COMPONENTS

Torque Converter Housing

Torque Converter

3201

3202

3201-240

BV22

BVACAB

44

30

BU

EV

45C

45B

AC

25A

AI

25

BA

EP

AO

3202-102

28A

28

BL

21

45C45A

45B

45

6626

46

46B

46A

29

46C

46E

46D

56B 56

56A

56E

25A

25

ADEF

AZ

EU

AM 30

AA

24

23

32A

BQ

CR

11

BP

22F22B

22

32

22C

CP

5253

54


Section 2

2-442-44



3203

3204

64

42A

25H

25D

22

24

24D

24A

24A

22A

24L

3203-141

AT

46B

46A

46

25E

58

24B

57A

57

45D

45A

AQ

45

10

42A42

50

4140

4140

4140

4140

4140

4140

4140

4140

CN

40

AJ

43

22

25

22A

25C

11

4250

4140

4140

4140

4140

4140

4140

4140

4140

CN

40

AJ

43

25H

3204-086

66

66A

66B

66C

AK

AP

AO

44C

43C44A

43

44

46

Refer to3203-10

Refer to3203-11


Section 2

2-45

Control Valve

Torque Converter Piping

3206

3213

3206-131BX

EA

AV

50

EQCB

RO

DI

DJ

51

ED

CJ

32

CXEF

44C

BW

AW

GN

31

CY

EH

CG

BC

31

41

JF

BB

GW

3213-161

10

AT

30

30A

HU

HT


Section 2

2-462-46

Direction Switch

5701

5701-511A

SH

LD

AT

KA

LG

97SJ NT

AI

14

LG

KA

SHAI

LG

QB

A2


Section 2

2-47

TROUBLESHOOTINGIn

spec

tion

afte

r dis

asse

mbl

y

Insp

ectio

n on

the

vehi

cle

Con

trol v

alve

sO

ther

then

con

trol v

alve

s (to

rque

con

verte

r & tr

ansm

issio

n)

Regulator valve

Inching valve

Accumulator

Solenoid valve for F and R

In-line strainer

Oil strainer

Torque converter

Oil pump

Clutch drum for F and R

Gears and bearings

Direction lever switch and neutral switch

ATF level and property

Inching lever and wire cable

Oil pressure test

Stall test

Star

ting

defe

ct

The

vehi

cle

does

not

mov

e w

hen

F is

sel

ecte

d.

The

vehi

cle

does

not

mov

e w

hen

R is

sel

ecte

d.

The

vehi

cle

does

not

mov

e fo

r any

rang

e se

lect

ion.

The

vehi

cle

mov

es re

gard

less

of N

sel

ectio

n.

Exc

essi

ve s

hock

up

on s

tarti

ng

(shi

fting

).

Star

ting

(shi

fting

)N

→ F

N →

R

Star

ting

(inch

ing)

At F

At R

Exc

essi

ve ti

me

lag

upon

sta

rting

(s

hifti

ng)

N →

F

N →

R

Upo

n sw

itch-

back

F ↔

R

Slip

ping

At F

At R

Oth

ers

The

star

ting

mot

or d

oes

not r

un a

t N.

The

star

ting

mot

or ru

ns a

t oth

er th

an N

.

Inch

ing

oper

atio

n fa

ils.

Tran

smis

sion

ove

rhea

ting

or o

il sp

outin

g fro

m

brea

ther

.

Abno

rmal

noi

se.


Section 2

2-482-48

TORQUE CONVERTER


Removal Procedure1 Drain torque converter oil.

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



3


Section 2

2-49


Disassembly Procedure1 Remove the pump impeller. [Point 1]

2 Remove the pump boss ASSY. [Point 2]

3 Remove the stator No.2 parts. [Point 3]

4 Remove the stator No.1 parts. [Point 4]

5 Remove the turbine runner.

6 Remove the pilot bearing. [Point 5]


1

1

2

2

3

4

5

6

T = 18.6 ~ 24.5

(190 ~ 250)

[13.1 ~ 18.1]


Section 2

2-502-50


Disassembly:Put match marks on the pump impeller and drive cover.

Reassembly:Align the match marks on the pump impeller and drive cover.

[Point 2]

Disassembly:

SST 09950-76018-71................................. (1)(09950-60010)09950-76020-71................................. (2)(09950-70010)

Reassembly:

SST 09950-76019-71................................. (1)(09950-60020)09950-76020-71................................. (2)(09950-70010)

Inspection:Measure the outside diameter at the oil seal sliding surface.


Limit: 69.85 mm (2.7450 in)


Limit: 0.3 mm (0.012 in)

Match mark

SST (1)

SST (2)

SST (2)

SST (1)


Section 2

2-51


Limit: 0.3 mm (0.012 in)

[Point 3]

Disassembly:Slowly remove the stator hub because rollers, springs andspring caps come off at a time.

Inspection:Measure the roller outside diameter.


Limit: 8.17 mm (0.322 in)

Inspection:Measure the clearance between the stator hub and stator cam.

Standard: 0.08 ~ 0.12 mm (0.0031 ~ 0.0047 in)

Limit: 0.2 mm (0.0079 in)

Reassembly:Stator installation

1. Apply grease on the springs and spring caps, and install themwith tweezers or a similar tool.

2. Install rollers while pushing each spring cap with a screwdriver.


Section 2

2-522-52

3. Install the stator hub on the stator by turning it in the unlockingdirection.

4. Check the one-way clutch function after reassembly.

[Point 4]

Reassembly:Never install the one-way clutch, thrust bearing and stator hubin wrong directions. (See the illustration)

Reassembly:Check the one-way clutch function after reassembly.

[Point 5]

Disassembly:

SST 09320-23000-71

Turningdirection

Hold

Thrust bearing

Color: Black Stator-hub One-way clutch Color: Black

Turningdirection

Hold

SST


Section 2

2-53

Reassembly:

SST 09950-76018-71................................. (1)(09950-60010)09950-76020-71................................. (2)(09950-70010)

SST (1)

SST (2)


Section 2

2-542-54




Front insulator set bolt T = 68.0 ~ 102.0 (700 ~ 1050) [50.6 ~ 76.0]


Drive plate set bolt (for connecting to engine crankshaft)

4Y engine vehicleT = 56.8 ~ 64.7 (580 ~ 660) [42.0 ~ 47.8]

1DZ-II engine vehicleT = 76.4 ~ 93.1 (780 ~ 950) [56.4 ~ 68.7]


28 26

823


Section 2

2-55

Removal Procedure1 Remove the engine hood. (Refer to page 9-9)

2 Remove the lower panel.


4 Drain coolant.

5 Remove the battery.

6 Remove the sedimenter bracket set bolt and leave it free. (1DZ-II engine vehicle)

7 Disconnect the accelerator wire. (1DZ-II engine vehicle)

8 Disconnect the fuel hose.

9 Remove the relay block and leave it free.

10 Remove the battery set plate.

11 Remove the air cleaner and air inlet.

12 Remove the exhaust pipe cover plate.

13 Disconnect the exhaust pipe.

14 Remove the RH side step and side cover.

15 Disconnect the main harness connector inside the RH side cover.

16 Disconnect the oil pump-to-oil control valve hose.


18 Disconnect the torque converter cooler hose (on the transmission side) and drain oil from the torque converter.[Point 1]

19 Disconnect the torque converter cooler hose (on the radiator side). [Point 2]

20 Disconnect the water hose.

21 Remove the radiator and fan shroud.

22 Remove the under cover.

23 Drain the brake cooling oil. (Wet Brake model) (Refer to page 8-62)

24 Remove the brake cooling oil tank. (Wet Brake model) (Refer to page 8-61)

25 Disconnect the wiring and wire harness clamps around the engine and transmission.

26 Remove the oil pump set bolt, and leave it free.

27 Remove the propeller shaft under cover and propeller shaft. (Dry Brake model: Refer to page 3-4, Wet Brake model: Refer to page 3-5)

28 Remove the engine mount nut.

29 Attach the SST to the engine W/ torque converter and transmission ASSY. [Point 3]

30 Remove the front insulator set bolt.

31 Remove the engine W/ torque converter & transmission ASSY. [Point 4]

32 Remove the cover plate.

33 Remove the drive plate set bolts (6 bolts). [Point 5]

34 Disconnect the engine ASSY from the torque converter housing.


Section 2

2-562-56


Note:After installing the engine ASSY, perform air bleeding of the fuel system. (1DZ-II engine vehicle) (Refer topage 1-11)


Removal:Put match marks on the transmission case and torqueconverter cooler hose.

[Point 2]

Removal:Put match marks on the radiator and torque converter coolerhose.

[Point 3]

Removal•Installation:

SST 09010-20111-71 ................................. (1)09010-23320-71................................. (2)

[Point 4]

Removal•Installation:Move the SST hook position to adjust the balance.

SST(2)SST(1)

SST


Section 2

2-57

[Point 5]

Removal•Installation:Turn the flywheel using the crankshaft pulley set bolt.

Crankshaft pulley set bolt


Section 2

2-582-58

TRANSMISSION ASSY


2

3

4

5

6

7

8

9

10

11

12

13

14

14

1516

17

18

19 20

21

22

23

24

25

26

26

26

26

27

27

2829


Section 2

2-59

Disassembly Procedure1 Drain the torque converter oil.

2 Remove the torque converter. (For disassembly, inspection and reassembly of torque converter ASSY, see page 2-49)

3 Remove the solenoid valve. [Point 1]

4 Remove the inching valve ASSY.

5 Remove the inching spool and spring. [Point 2]

6 Remove the coin filter from the inching valve body. [Point 3]

7 Remove the oil seal from the inching valve body. [Point 4]

8 Remove the accumulator valve. [Point 5]

9 Remove the regulator valve. [Point 6]


11 Remove the oil strainer.

12 Separate the torque converter case and transmission case. [Point 8]

13 Remove the idle gear W/ bearing. [Point 9]

14 Remove the bearing from the idle gear. [Point 10]

15 Remove the stator shaft No.1 W/ bearing. [Point 11]

16 Remove the bearing from the stator shaft No.1. [Point 12]

17 Remove the output shaft bearing from torque converter case. [Point 13]

18 Remove the stator shaft No.2 & oil pump ASSY. (For disassembly, inspection and reassembly of stator shaft No.2 & oil pump ASSY, see page 2-69) [Point 14]

19 Remove the reverse shaft bearing from torque converter case. [Point 15]

20 Remove the reverse shaft counter gear. [Point 16]

21 Remove the main shaft counter gear W/ bearing. [Point 17]

22 Remove the main shaft counter gear bearing. [Point 18]

23 Remove the output shaft ASSY. [Point 19]

24 Remove the main shaft ASSY (clutch drum ASSY No.1 W/ clutch gear). (For disassembly, inspection and reassembly of clutch drum ASSY, see page 2-71)

25 Remove the reverse shaft ASSY (clutch drum ASSY No.2 W/ clutch gear). (For disassembly, inspection and reassembly of clutch drum ASSY, see page 2-71)

26 Remove the shaft seal ring and bearing. [Point 20]

27 Remove the clutch gear and clutch gear bearing. [Point 21]

28 Remove the output shaft oil seal. [Point 22]

29 Remove the output shaft bearing from transmission case. [Point 23]


Section 2

2-602-60


Note:Apply sealing agent (08826-76001-71 (08826-00080)) on the oil strainer surface to be mounted on the torqueconverter case.


Inspection:Inspect the solenoid valve for continuity.Between 1 and 2: ContinuityBetween 3 and 4: Continuity

[Point 2]

Inspection:Measure the free length of the inching valve spring.

mm (in)

Reassembly:Never install the spring retainer in a wrong direction.

[Point 3]

Inspection:Inspect and wash the coin filter to eliminate clogging.

1: R (+)2: R (–)

3: F (+)4: F (–)

Standard Limit

Inner spring 27 (1.06) 24 (0.94)

Outer spring 63.3 (2.49) 58 (2.28)


Section 2

2-61

[Point 4]

Disassembly:

SST 09950-76018-71................................. (1)(09950-60010)09950-76020-71................................. (2)(09950-70010)

[Point 5]

Inspection:Measure the free length of the accumulator spring.

mm (in)

[Point 6]

Disassembly•Reassembly:Use the service bolt for disassembly and reassembly of theregulator valve spool.

Service bolt size: M6 x 1.0

Inspection:Measure the free length of the regulator valve spring.

Standard: 110 mm (4.331 in)

Limit: 98 mm (3.858 in)

[Point 7]


SST 09228-76004-71(09228-07501)

SST (1)

SST (2)

Standard Limit

Inner spring 70 (2.756) 62 (2.441)

Outer spring 122 (4.803) 108 (4.252)

Service bolt

SST


Section 2

2-622-62

[Point 8]


SST 09010-13200-71

Reassembly:Set the O-ring in the specified position on the case matingsurface.

Reassembly:When joining the case, use a screwdriver and adjust so thatthe No.1 stator gear meshes with the counter shaft gear.

[Point 9]

Disassembly:

SST 09950-76014-71(09950-40011)

Reassembly:Use a round bar and install the idle gear W/ bearing.

SST

O-ring

SST


Section 2

2-63

[Point 10]

Disassembly:

SST 09950-76018-71................................. (1)(09950-60010)09950-76020-71................................. (2)(09950-70010)

Reassembly:

SST 09950-76018-71................................. (1)(09950-60010)09950-76020-71................................. (2)(09950-70010)

[Point 11]


Limit: 0.3 mm (0.012 in)

[Point 12]

Disassembly:

SST 09950-76014-71................................. (1)(09950-40011)09950-76018-71................................. (2)(09950-60010)

Reassembly:Use a round bar and install the bearing.

SST (1)

SST (2)

SST (1)

SST (2)

SST (1)

SST (2)


Section 2

2-642-64

[Point 13]

Disassembly:

SST 09320-23000-71

Reassembly:

SST 09950-76018-71................................. (1)(09950-60010)09950-76020-71................................. (2)(09950-70010)

[Point 14]

Disassembly:Use a round bar and remove the stator shaft No.2 & oil pumpASSY.

[Point 15]

Disassembly:

SST 09950-76014-71(09950-40011)

Reassembly:

SST 09950-76019-71................................. (1)(09950-60020)09950-76020-71................................. (2)(09950-70010)

SST

SST (1) SST (2)

SST

SST (1)

SST (2)


Section 2

2-65

[Point 16]

Disassembly:Use a bar and remove reverse shaft counter gear No.1.

Disassembly:Use a bar and remove reverse shaft counter gear No.2.

[Point 17]

Disassembly:Use a bar and remove the main shaft counter gear w/ bearing.

[Point 18]

Reassembly:Install the bearing in the correct direction (See the illustration.)

[Point 19]

Disassembly:Remove the output shaft ASSY by tapping its tip end with aplastic hammer.

A

A>BB


Section 2

2-662-66

Reassembly:Install the output shaft ASSY by tapping the joint using aplastic hammer.

[Point 20]

Inspection:Measure the side clearance of each shaft seal ring.

mm (in)

Inspection:Measure the seal ring side clearance. (Main shaft only)

Limit: 0.3 mm (0.012 in)

Disassembly:Remove the bearing using the SST and a press.

SST 09420-23002-71

Reassembly:Use a round bar and install the bearing.

Limit

Main shaft 0.3 (0.012)

Reverse shaft 0.3 (0.012)

SST


Section 2

2-67

[Point 21]

Disassembly:Remove the clutch gear W/ bearing using the SST and apress.

SST 09420-23002-71

Disassembly:

SST 09950-76019-71................................. (1)(09950-60020)09950-76020-71................................. (2)(09950-70010)

Reassembly:After aligning the clutch disc serration using a screwdriver orthe like, reassemble the clutch gear.

Reassembly:

1. Insert a plate between the clutch gear and clutch drum asillustrated, and temporarily install the gear first.

2. Use a round bar and install the clutch gear bearing to theclutch gear.

3. Remove the plate.

[Point 22]

Reassembly:

SST 09150-10170-71

SST

SST (1)

SST (2)

Plate

SST


Section 2

2-682-68

[Point 23]

Disassembly:

SST 09950-76018-71................................. (1)(09950-60010)09950-76020-71................................. (2)(09950-70010)

Reassembly:

SST 09950-76019-71................................. (1)(09950-60020)09950-76020-71................................. (2)(09950-70010)

SST (1)

SST (2)

SST (1)

SST (2)


Section 2

2-69

STATOR SHAFT NO.2 & OIL PUMP ASSY


Disassembly Procedure1 Remove the stator shaft NO.2. [Point 1]

2 Remove the oil pump gear. [Point 2]



Point Operations[Point 1]Insert flathead screwdrivers between the stator shaft No. 2 and oilpump ASSY to separate them.

2

1

3


Section 2

2-702-70

Inspection:Measure the outside diameter of the stator shaft No.2 in slidingcontact with the pump drive gear.


Limit: 47.9 mm (1.886 in)

[Point 2]Inspection:

Measure the clearance between the oil pump driven gear andpump body.

Standard: 0.14 ~ 0.20 mm (0.0055 ~ 0.0079 in)

Limit: 0.3 mm (0.012 in)

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

Standard: 0.06 ~ 0.10 mm (0.0024 ~ 0.0039 in)

Limit: 0.13 mm (0.0051 in)

Inspection:Measure the clearance between the oil pump drive gear bushand stator shaft.

Standard: 0.025 ~ 0.066 mm (0.00098 ~ 0.00260 in)

Limit: 0.15 mm (0.0059 in)

[Point 3]

Reassembly:

SST 09370-20270-71

SST


Section 2

2-71

CLUTCH DRUM ASSY


Disassembly Procedure1 Remove the snap ring.

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

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

4 Remove the clutch piston. [Point 3]


1

2

3

4


Section 2

2-722-72


Inspection:Measure the camber plate warp height.


Limit: 3.3 mm (0.130 in)

Inspection:Measure the thicknesses of the pressure plate, clutch disc andclutch plate.Standard:

mm (in)

Reassembly:Install the camber plate with the “H” mark facing upward.

Reassembly:Install the camber plate with the chamfered face facingupward.

Reassembly:Carefully install each plate in the correct order.

Clearance between snap ring and pressure plate.

Standard: A = 3.1 mm (0.122 in) (Reference)

Clutch plate Clutch disc

Standard Limit

Clutch plate 1.6 (0.063) 1.4 (0.055)

Clutch disc 2.6 (0.102) 2.3 (0.091)

“H” mark

Upward

Downward

A


Section 2

2-73

[Point 2]

Disassembly•Reassembly:Use the SST to compress the return spring for snap ringinstallation or removal. Bind two hooks of the SST with a wireor cord as illustrated to prevent departure from the clutchdrum.

SST 09220-33901-71

Caution:Carefully operate with sufficient check since the hook maycome off from the clutch drum to cause the spring to fly outwhile the SST is in use.

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


Limit: 90 mm (3.54 in)


Measure the side clearance of the seal ring.

Limit: 0.30 mm (0.012 in)

Inspection:Measure the side clearance of the piston ring.

Limit: 0.4 mm (0.0157 in)

SST


Section 2

2-742-74

DIRECTION SWITCH ASSY

REMOVAL·INSTALLATION

Disassembly Procedure1 Remove the steering column cover.


3 Remove the direction switch ASSY. [Point 1]



Inspection:Inspect for continuity between the pins of the switch connector.

1

1

3

LH spec.15: —16: IG217: N18: IG119: VF20: VF221: ST22: Ra23: VR

VF : Forward solenoidVF2 : Forward (F2) solenoidVR : Reverse solenoidST : Starting motor relayRa : Backup lamp & buzzer

RH spec.15: VR16: Ra17: ST18: VF219: VF20: IG121: N22: IG223: —

23 22 21 20 19 18 17 16 15

32 31 30 29 28 27 26 25 24

P T

F1

N

Rr

N IG1 IG2 VF ST VR Ra

R

Ra

(P:Position, T:Terminal No., :Continuous)


Section 2

2-75

OIL PRESSURE MEASUREMENT AND STALL TEST (1 SPEED TORQUE CONVERTER (STD))1. Maintain the vehicle horizontally and warm up the engine with

the direction switch at the N position.

2. Measure the oil level.

(1) Stop the engine, and after 30 seconds has passed,inspect the oil level using the level guage.

(2) If the oil level is not between F (upper limit) and L (lowerlimit), adjust it to an appropriate level.

3. Measure the oil pressure.

(1) Check and adjust the engine speed.

(2) Stop the engine and jack up at the front axle to raisewheels (both tires).

(3) Set the oil pressure gauge. (If three oil pressure gaugesare available, measure the main, clutch and torqueconverter outlet pressures at a time.)Use the adapter (SST) for the main pressure and clutchpressure detection port.SST 09350-23320-71(SST thread size: Valve side 5/16 UNF, Oil pressuregauge side PT1/8)

Use the adapter (SST) for the outlet pressure detectionport. (Wet brake model only)SST 09321-26600-71

(4) Start the engine, set the direction switch to the N position.Measure the main pressures at idle and 2000 rpm, andthe torque converter outlet pressure at 2000 rpm.

(5) Operate the direction switch to the F and R positions, andmeasure the respective clutch working pressures at idleand at 2000 rpm.

Note:Do not step on the inching pedal while measuring oil pressure.

Standard:kPa (kgf/cm2) [psi]

Front

Back

Clutch pressure (F)Main pressure

Outlet pressure

Clutch pressure (R)

Outlet pressure

SST

Wet brake

model

Detecting pressure Plug size Idle 2000 rpm

Main pressure PT1/8 (SST) 735 ~ 1324 (7.5 ~ 13.5) [106.6 ~ 192.0] 890 ~ 1270 (9.1 ~ 13.0) [129 ~ 185]

Clutch pressure ↑ ↑ 890 ~ 1270 (9.1 ~ 13.0) [129 ~ 185]

Torque converter outlet pressure PT1/8 — 80 ~ 540 (0.8 ~ 5.5) [11.3 ~ 78.2]


Section 2

2-762-76

4. Carry out the stall test.

(1) Load cargo having near the permissible maximum load,firmly set stoppers at the front and rear wheels, andactivate the parking brake.

Caution:Prevent the vehicle from moving by pulling at the rear by awire as shown, to perform the stall test safely.

(2) Warm up the engine and measure the idle speed, no-loadstatic maximum revolution and relief down.

(3) Set the direction switch to the forward position, depressthe accelerator pedal all the way and measure the stallspeed after the engine speed is stabilized.

Standard:4Y: Approx. 2200 rpm1DZ-II: Approx. 2200 rpm

Accelerator pedal


Section 2

2-77

OIL PRESSURE MEASUREMENT AND STALL TEST (2 STATORS TORQUE CONVERTER (OPT))1. Maintain the vehicle horizontally and warm up the engine with





3. Measure the oil pressure.



(3) Set the oil pressure gauge. (If three oil pressure gaugesare available, measure the main, clutch and torqueconverter outlet pressures at a time.)Use the adapter (SST) for the outlet pressure detectionport. (Wet brake model only)SST 09321-26600-71

(4) Start the engine, set the direction switch to the N position.Measure the main pressures at idle and 1500 rpm, andthe torque converter outlet pressure at 1500 rpm.

(5) Operate the direction switch to the F and R positions, andmeasure the respective clutch working pressures at idleand at 1500 rpm.



Clutch pressure (F)

Clutch pressure (R) Main pressure

Outlet pressure

SST

Wet brake

model

Outlet pressure


Main pressure PT1/8 600 or more (6 or more) [85 or more] 1000 ~ 1400 (10.2 ~ 14.2) [145 ~ 203]

Clutch pressure ↑ ↑ ↑

Torque converter outlet pressure ↑ — 100 ~ 400 (1.02 ~ 4.1) [14.5 ~ 58]


Section 2

2-782-78






Standard:4Y: Approx. 1950 rpm1DZ-II: Approx. 1950 rpm

Accelerator pedal


Section 2

2-1

0123456789101112131415161718192021E

TORQUE CONVERTER & TRANSMISSIONPage

GENERAL.............................................................2.1-2HYDRAULIC CIRCUIT DIAGRAM .......................2.1-4SPECIFICATIONS ................................................2.1-5COMPONENTS ....................................................2.1-6TROUBLESHOOTING........................................2.1-12CONTROL VALVE ASSY ...................................2.1-13

REMOVAL·INSTALLATION ...................................2.1-13DISASSEMBLY·INSPECTION·REASSEMBLY .........2.1-14

TORQUE CONVERTER·OIL PUMP...................2.1-18REMOVAL·INSTALLATION ...................................2.1-18

TORQUE CONVERTER & TRANSMISSION ASSY ................................................................2.1-20REMOVAL·INSTALLATION ...................................2.1-20

TRANSMISSION ASSY......................................2.1-24DISASSEMBLY·INSPECTION·REASSEMBLY .........2.1-24

CLUTCH DRUM ASSY.......................................2.1-27DISASSEMBLY·INSPECTION·REASSEMBLY .........2.1-27

DIRECTION SWITCH ASSY ..............................2.1-31REMOVAL·INSTALLATION ...................................2.1-31

OIL PRESSURE MEASUREMENT AND STALL TEST.....................................................2.1-32

kalstatt

Text Box

2.1-1

kalstatt

Text Box

2.1

kalstatt

Text Box

8FGCU15,18,SU20

2-22-2

GENERAL

F: F

orw

ard

R: R

ever

se

RF

Transmission Cu1 ton series

Section 2.1

kalstatt

Text Box

2.1-2

2-3

0123456789101112131415161718192021E

Control Valve

Filte

r

A

B

C

C

A -

A

B -

BSo

leno

id

valv

eSo

leno

id

valv

e

Sel

ecto

r val

ve(F

orw

ard)

Saf

ety

valv

e

Inch

ing

valv

e

Acc

umul

ator

va

lve

A

B

Sel

ecto

r val

ve(R

ever

se)


Section 2.1

kalstatt

Text Box

2.1-3

kalstatt

Text Box

2.1-3

kalstatt

Text Box

2.1

2-42-4

HYDRAULIC CIRCUIT DIAGRAM

Clu

tch

Inch

ing

valv

e

SO

L (F

)S

OL

(R)

FO

NO

FF

RO

FFO

N

NO

FFO

FF

F R

Accu

mul

ator

va

lve

Forw

ard

sele

ctor

va

lve

Rev

erse

se

lect

or

valv

e

SO

L. F

SO

L. R

Filte

r

Oil

filte

r

T/C

Oil

cool

er

T/C

inle

t rel

ief v

alve

Oil

pum

p

Oil

stra

iner

Safe

ty

valv

e

Reg

ulat

or v

alve


Section 2.1

kalstatt

Text Box

2.1-4

2-5

0123456789101112131415161718192021E

SPECIFICATIONSManufacturer EXEDY

Torque converter type 3-element, 1-stage, 2-phase



Gear ratioForward 1.889

Reverse 1.889

Main pressure At idling 880 (9) [130] or more

kPa (kgf/cm2) [psi] At 2000 rpm 980 ~ 1370 (10 ~ 14) [140 ~ 200]

Clutch operating pressure At idling 880 (9) [130] or more


Torque converter inlet pressure At idling 147 ~ 290 (1.5 ~ 3) [21 ~ 40]


Torque converter outlet pressure At idling 100 ~ 200 (1 ~ 2) [10 ~ 30]

kPa (kgf/cm2) [psi] At 2000 rpm 245 ~ 343 (2.5 ~ 3.5) [36 ~ 52]

Lubricating pressure At idling 29 (0.3) [4.3] or more

kPa (kgf/cm2) [psi] At 2000 rpm 100 ~ 245 (1 ~ 2.5) [10 ~ 36]

Torque converter oil capacity(Excluding oil cooler) l (US gal) 9.1 ~ 10.3 (2.40 ~ 2.72)



Section 2.1

kalstatt

Text Box

2.1-5

kalstatt

Text Box

2.1

2-62-6

COMPONENTSTorque Converter Housing

3201

3201

3201-235

00CT

CT

AK

BA

GH

JO

AR DR

DR

42

DR

AR

DJ

DJASCW

K

K

3201-233

03K=(INCL. )

01K=(INCL. )

K

KK

K

K

K

K

K

KK

K

K

K

K

K

K

KK

KK

K

K

K

K

KK


Section 2.1

kalstatt

Text Box

2.1-6

2-7

Torque Converter

3201

3202

3201-234

AF AD

AI

AI

HU

AI

22

EP

KN

30

DP

BT

EC

3202-097

AR

AS

20

AZ

AL

AS

AL

AL

ALAL


Section 2.1

kalstatt

Text Box

2.1-7

2-82-8


3202

3203

3202-098

01

AA

EG22

24

23

30

AX

AH

EH

11


Section 2.1

kalstatt

Text Box

2.1-8

2-9


Control Valve

3204

3206

3206-107B

TL

AB

RH

DU

TN

EK

DC

TJ

AF

BE

TK

AB

UH

BXBX

BBKB

BGJF

BG

HF

UG

TU

DJ

TU

DI

CD

51

GK BX

CB

RA

DK

FK

DT

AI

AY

EV

AV

50

12

GJ

FH

GI

DDDE

TN

TN

TH

AQ

HF

UG

AW

44

BC

GW

HF

LA

KZ

14

BD

UF

TM

UE

CO

14

AD


Section 2.1

kalstatt

Text Box

2.1-9

2-102-10

Torque Converter Piping

3213

3213

3213-157

BA

FN75

FN

74

FN

BA

BA

AC

10

GL

AO

AH

BP

AH

BA

AX

GX

30A

30

AY

3213-156


Section 2.1

kalstatt

Text Box

2.1-10

2-11

Direction Switch

5701

5701-511A

SH

LD

AT

KA

LG

97SJ NT

AI

14

LG

KA

SHAI

LG

QB

A2


Section 2.1

kalstatt

Text Box

2.1-11

2-122-12

TROUBLESHOOTINGD

isas

sem

bly

and

insp

ectio

n

On-

boar

d in

spec

tion

Con

trol v

alve

Com

pone

nts

othe

r tha

n co

ntro

l va

lves

(tor

que

conv

erte

r &

trans

mis

sion

)

Inching valveShift change valve for FShift change valve for RSafety valveAccumulator valveSolenoid valve for FSolenoid valve for ROrifice, Coin filter

Oil strainerTorque converterOil pumpClutch drum for FClutch drum for RGear, bearingRegulator valveT/C inlet valveOrifice

Shift lever switchATF level and qualityInching lever, and wire cableOil pressure testStall test

Faul

ty s

tarti

ngN

o st

artin

g at

F

No

star

ting

at R

No

star

ting

at a

ny ra

nges

Star

t at N

rang

e

Larg

e sh

ock

at s

tarti

ng

(shi

fting

)A

t sta

rting

afte

r sh

iftin

gA

t N →

F

At N

→ R

Inch

ing

star

tA

t F

At R

Larg

e tim

e la

g at

sta

rting

(s

hifti

ng)

At N

→ F

At N

→ R

Inch

ing

star

t A

t F

At R

Slip

page

At F

At R

Oth

ers

Ove

rhea

ting

of tr

ansm

issi

on

Abno

rmal

noi

se


Section 2.1

kalstatt

Text Box

2.1-12

2-13

CONTROL VALVE ASSY


Removal Procedure1 Remove the rear toe board, lower panel and front toe boad.

2 Remove the inching lever pin.

3 Disconnect the electrical wiring.

4 Remove the control valve ASSY.


4

2

T = 31.4 ~ 37.2(320 ~ 380)[23.2 ~ 27.5]

*: It is unnecessary to remove this bolt here.

3*


Section 2.1

kalstatt

Text Box

2.1-13

2-142-14


Disassembly Procedure1 Remove the cover. [Point 1]

2 Remove the inching valve. [Point 2]

3 Remove the selector valve (for forward). [Point 3]

4 Remove the safety valve. [Point 4]

5 Remove the selector valve (for reverse). [Point 3]

6 Remove the accumulator valve.

7 Remove the valve body B ASSY. [Point 5]

8 Remove the coin filter and O-ring. [Point 6]

9 Remove the solenoid valve. [Point 7]



9

7

10

2

2

T = 31.4 ~ 37.2(320 ~ 380)[23.2 ~ 27.5]

T = 12.7 ~ 14.7(130 ~ 150)[9.41 ~ 10.9]

T =12.7 ~ 14.7 (130 ~ 150)[9.41 ~ 10.9]

2

6

9

8

45

1

3


Section 2.1

kalstatt

Text Box

2.1-14

2-15

Point Operations[Point 1]Disassembly:

Remove the cover slowly. Carefully operate since each valvemay be thrown out by the spring force.

[Point 2]Disassembly:

The washer can be removed downward from the valve bodywhen the inching spool is extracted.



Measure the clearance between the selector valve spool andvalve body.

Standard: 0.013 ~ 0.043 mm (0.00051 ~ 0.00169 in)

Limit: 0.085 mm (0.00335 in)

Washer


Inching valve spring(large diameter side)

77.0 (3.031)

75.2 (2.961)

Inching valve spring(small diameter side)

30.8 (1.213)

29.9 (1.177)

Accumulator spring(large diameter side)

66.5(2.618)

64.8(2.551)

Accumulator spring(small diameter side)

88.8(3.496)

88.1(3.469)

Selector valve and safety valve spring

27.8(1.094)

26.4(1.039)


Section 2.1

kalstatt

Text Box

2.1-15

2-162-16

Reassembly:Correct selector valve spring positions are as shown in theillustration. Do not install in wrong position.The selector valve spool may be installed in either direction.


Measure the clearance between the safety valve spool andvalve body.

Standard: 0.013 ~ 0.043 mm (0.00051 ~ 0.00169 in)

Limit: 0.085 mm (0.00335 in)

Reassembly:Do not install the safety valve spool in an incorrect direction.(Check the groove position.)


Inspect and wash the orifice to eliminate clogging.

Reassembly:If the orifice has been removed, apply thread tightener (08833-00070) at the time of assembly, and tighten to the specifiedtorque.

T = 8.3 N·m (85 kgf·cm) [6.1 ft·lbf]


Inspect and wash the coin filter to eliminate clogging.

→

→

→

Groove

→

Groove


Section 2.1

kalstatt

Text Box

2.1-16

2-17

Reassembly:Install the coil filter with its chamfered side facing down.


Check continuity of solenoid.

[Point 8]Reassembly:

SST 09950-76018-71................................. (1)(09950-60010)09950-76020-71................................. (2)(09950-70010)

After installation, apply grease on the oil seal lip portion.

Chamfering

SST (2)

SST (1)


Section 2.1

kalstatt

Text Box

2.1-17

2-182-18

TORQUE CONVERTER·OIL PUMP


Removal Procedure1 Drain the torque converter oil.

2 Remove the engine. (See page 1-5)

3 Remove the torque converter ASSY. [Point 1]

4 Remove the oil pump with stator shaft.

5 Remove the stator shaft.

6 Remove the oil pump gear. [Point 2]



3

4

T = 20.6 ~ 25.5 (210 ~ 260)[15.2 ~ 18.8]


Section 2.1

kalstatt

Text Box

2.1-18

2-19

Point Operations[Point 1]Inspection:

Inspect the outside diameter of the torque converter oil pumpboss.

Standard: 41.915 ~ 41.965 mm (1.65020 ~ 1.65217 in)

Limit: 41.815 mm (1.64626 in)


Inspect the clearance between the gear pump case and pumpgear.

Standard: 0.030 ~ 0.065 mm (0.00118 ~ 0.00256 in)

Limit: 0.1 mm (0.004 in)

Inspection:Inspect the clearance between the driven gear and pumpbody.

Standard: 0.17 ~ 0.23 mm (0.0067 ~ 0.0091 in)

Limit: 0.3 mm (0.012 in)

[Point 3]Reassembly:

SST 09950-76018-71................................. (1)(09950-60010)09950-76020-71................................. (2)(09950-70010)

After installation, apply grease on the oil seal lip portion.

SST (2)

SST (1)


Section 2.1

kalstatt

Text Box

2.1-19

2-202-20




Differential carrier set bolt (for connecting to differential housing) T = 49.0 ~ 78.4 (500 ~ 800) [36.2 ~ 57.9]

Differential carrier set bolt (for connecting to torque converter housing) T = 49.0 ~ 78.4 (500 ~ 800) [36.2 ~ 57.9]

Front axle shaft set bolt T = 98.1 ~ 127.5 (1000 ~ 1300) [72.35 ~ 94.06]


Drive plate set bolt (for connecting to engine crankshaft) T = 56.8 ~ 64.7 (580 ~ 660) [42.0 ~ 47.8]


10

145


Section 2.1

kalstatt

Text Box

2.1-20

2-21

Removal Procedure1 Remove the radiator cover.

2 Remove the counterweight.

3 Perform steps 2 through 16 of the engine removal procedure. (Refer to page 1-5)

4 Disconnect each pipe from the oil control valve. [Point 1]

5 Disconnect the electrical wiring.


7 Disconnect the torque converter cooler hoses.

8 Drain differential oil. [Point 2]

9 Remove the axle shaft. [Point 3]

10 Attach the SST to the engine W/torque converter & transmission ASSY. [Point 4]

11 Remove the engine mounting nuts.

12 Slightly hoist the engine W/torque converter & transmission ASSY. [Point 5]

13 Remove the differential carrier set bolts (for connecting to differential housing).

14 Remove the engine W/torque converter & transmission ASSY. [Point 6]

15 Drain torque converter oil.

16 Remove the differential ASSY. [Point 7]

17 Remove the cover plate, and remove the drive plate set bolts. (6 pcs.) [Point 8]

18 Remove the torque converter & transmission ASSY.



Section 2.1

kalstatt

Text Box

2.1-21

2-222-22

Point Operations[Point 1]Removal•Installation:

Remove and install the pipes and fittings shown in theillustration on the left.

[Point 2]Installation:

Fill Hypoid gear oil to the specified level after installation.

A = within 4.5 mm (0.177 in)

[Point 3]Removal•Installation:

Carefully operate so as not to damage the oil seal by contactwith the axle shaft.


SST 09010-20111-71 ................................. (1)09010-23320-71................................. (2)

[Point 5]Removal:

Tentatively hoist up until the mounting bolt completely comesout from the hole in the frame.

SST(2)

SST(1)


Section 2.1

kalstatt

Text Box

2.1-22

2-23

[Point 6]Removal:

Move the SST hook position to adjust the balance.

[Point 7]Removal:

Sling wires on the differential carrier and hoist it slightly.Remove the set-bolts and use the service bolt for separation.Service bolt size: M10 × 1.5


Rotate the drive plate by using a crankshaft pulley set bolt.


Section 2.1

kalstatt

Text Box

2.1-23

2-242-24

TRANSMISSION ASSY


Disassembly Procedure1 Remove the control valve ASSY.


3 Remove the oil pump with stator shaft.

4 Remove the clutch drum ASSY. (For disassembly, inspection and reassembly of the clutch drum ASSY, see page 2.1-27.)

5 Remove the clutch drum shaft front bearing. [Point 1]

6 Remove the countergear.

7 Remove the countergear bearing. [Point 2]

8 Remove the cover, regulator spring, regulator piston, torque converter inlet relief spring and inlet relief piston.[Point 3]

9 Remove the oil strainer.



T = 57.8 ~ 74.5(590 ~ 760)[42.7 ~ 55.0]

T = 57.8 ~ 74.5(590 ~ 760)[42.7 ~ 55.0]

10

8

9

1

2

3

7

6

7

54


Section 2.1

kalstatt

Text Box

2.1-24

2-25

Point Operations[Point 1]Disassembly:

SST 09320-23000-71

Reassembly:SST 09950-76019-71................................. (1)

(09950-60020)09950-76020-71................................. (2)(09950-70010)


SST 09320-23000-71

Reassembly:SST 09950-76019-71................................. (1)

(09950-60020)09950-76020-71................................. (2)(09950-70010)


Remove the cover slowly. Otherwise, the spring may jump out.

SST

SST (2) SST (1)

SST

SST (2) SST (1)


Section 2.1

kalstatt

Text Box

2.1-25

2-262-26

Inspection:Measure the clearance between the regulator piston/torqueconverter inlet piston and the housing hole.

Standard: 0.02 ~ 0.058 mm (0.0008 ~ 0.00228 in)

Limit: 0.10 mm (0.0039 in)

Inspection:Measure the free length of the regulator valve spring.


Limit: 120.8 mm (4.756 in)

Inspection:Measure the free length of the torque converter inlet valvespring.


Limit: 99.4 mm (3.913 in)

[Point 4]Disassembly•Reassembly:

SST 09228-76004-71(09228-07501)

SST


Section 2.1

kalstatt

Text Box

2.1-26

2-27

CLUTCH DRUM ASSY


Disassembly Procedure1 Remove the seal ring. [Point 1]

2 Remove the bearing. [Point 2]

3 Remove the clutch gear (forward), bearing and collar. [Point 3]

4 Remove the clutch plates, clutch discs, clutch pressure plate and camber plate. [Point 4]

5 Remove the clutch spring. [Point 5]

6 Remove the piston and seal ring. [Point 6]

7 Remove the seal rings. [Point 1]

8 Remove the clutch gear (reverse), bearing and collar. [Point 3]

9 Remove the clutch plates, clutch discs, clutch pressure plate and camber plate. [Point 4]

10 Remove the clutch spring. [Point 5]

11 Remove the piston and seal ring. [Point 6]

1 2

4

3

6

5

11

10

9

8

7


Section 2.1

kalstatt

Text Box

2.1-27

2-282-28


Note:• Coat torque converter oil sufficiency on each part before assembly.• When installing the seal ring, carefully operate so as not to let its joint open.• Install the camber plate, clutch discs and clutch plate in the correct direction.

Point Operations[Point 1]Inspection:

Measure the seal ring width.

Standard: 2.28 ~ 2.33 mm (0.0898 ~ 0.0917 in)

Limit: 2.08 mm (0.0819 in)


SST 09950-76014-71(09950-40011)


SST 09950-76014-71(09950-40011)

Reassembly:After installing the clutch gear on the clutch drum, install thecollar, bearing and snap ring.

SST 09316-76008-71(09316-60011)

SST

SST

SST


Section 2.1

kalstatt

Text Box

2.1-28

2-29


Measure the clutch disc thickness.

Standard: 2.50 ~ 2.65 mm (0.0984 ~ 0.1043 in)

Limit: 2.3 mm (0.091 in)

Inspection:Measure thickness of the clutch plate.

Standard: 1.53 ~ 1.67 mm (0.0602 ~ 0.0657 in)

Limit: 1.4 mm (0.055 in)

Inspection:Measure height of the camber plate curving.

Standard: 2.85 ~ 3.15 mm (0.1122 ~ 0.1240 in)

Limit: 2.5 mm (0.098 in)

Reassembly:Install the clutch plate and clutch disc alternately on the clutchdrum, while applying torque converter oil.Do not install the camber plate in an incorrect direction. Install the pressure plate with its punched side facing upward.

Reassembly:Adjust the clearance between the pressure plate and snapring.

1. Install the camber plate, clutch disc, clutch plate, pressureplate and snap ring on the clutch drum.

2. Measure clearance between the pressure plate and snap ringusing thickness gauges.

Standard: 1.6 ~ 1.8 mm (0.063 ~ 0.071 in)

Limit: 4.0 mm (0.157 in)

Clutch disc

Pressure plate

Camber plate

Punched mark


Section 2.1

kalstatt

Text Box

2.1-29

2-302-30

3. If the measured value is out of the specified range, select asuitable pressure plate.

unit: mm (in)

[Point 5]Disassembly•Reassembly:

Compress the return spring using the SST and remove orinstall the snap ring.Tie two hooks of the SST by a wire or string as shown andsecure the hooks so that they will not disconnected from theclutch drum.SST 09220-22001-71

Caution:If the hooks are disconnected from the clutch drum while theSST is in use, spring will jump out, which is dangerous.

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


Limit: 51.8 mm (2.039 in)


Measure the piston outer seal ring width.

Standard: 2.40 ~ 2.45 mm (0.0945 ~ 0.0965 in)

Limit: 2.20 mm (0.0866 in)

Inspection:Measure the piston inner seal ring width.

Standard: 2.30 ~ 2.35 mm (0.0906 ~ 0.0925 in)

Limit: 2.10 mm (0.0827 in)

Punched mark A B C D E

Thickness 3.9(0.154)

4.1(0.161)

4.3(0.169)

4.5(0.177)

4.7(0.185)

SST


Section 2.1

kalstatt

Text Box

2.1-30

2-31

DIRECTION SWITCH ASSY

REMOVAL·INSTALLATION

Disassembly Procedure1 Remove the steering column cover.


3 Remove the direction switch ASSY. [Point 1]



Inspection:Inspect for continuity between the pins of the switch connector.

1

1

3

2

VF : Forward solenoidVR : Reverse solenoidST : Starting motor relayRa : Backup lamp & buzzer

LH spec.15: VR16: Ra17: ST19: VF20: IG121: N22: IG223: —

23 22 21 20 19 18 17 16 15

32 31 30 29 28 27 26 25 24

P T

F1

N

Rr

N IG1 IG2 VF ST VR Ra

R

Ra

(P: Position, T: Terminal No., : Continuous)


Section 2.1

kalstatt

Text Box

2.1-31

2-322-32

OIL PRESSURE MEASUREMENT AND STALL TEST1. Maintain the vehicle horizontally and warm up the engine with





3. Set the oil pressure gauge.



(3) Set the oil pressure gauge.

4. Measure the oil pressure

(1) Check the oil pressure when the engine speed is idlingand 2000 rpm.

(2) Start the engine, set the direction switch in the neutralposition, and measure the inlet pressure (A) and outletpressure (B).

(3) Start the engine, set the direction switch in the neutralposition and measure the lubrication pressure (C).

(4) Start the engine, set the direction switch in the neutralposition, and measure the main pressure (D).

(5) Start the engine, set the direction switch in the forward (E)or reverse (F) position, and measure the clutch pressure.Use the adapter (SST) for the clutch pressure detectionport (E) and (F).SST 09321-26600-71



C

E

F

SST

AD

Oil pressure measuring ports

A: Inlet pressure (size PT 1/8)

B: Outlet pressure (size PT 1/4)

C: Lubrication pressure (size PT 1/8)

D: Main pressure (size PT 1/8)

E: Clutch operating pressure (Forward)

(size PT 1/8)

F: Clutch operating pressure (Reverse)

(size PT 1/8)

B


Torque converter inlet pressure PT1/8 147 ~ 290 (1.5 ~ 3.0) [21 ~ 40] 390 ~ 690 (4.0 ~ 7.0) [60 ~ 100]

Torque converter outlet pressure PT1/4 100 ~ 200 (1.0 ~ 2.0) [10 ~ 30] 245 ~ 343 (2.5 ~ 3.5) [36 ~ 52]

Lubrucating pressure PT1/8 29 (0.3) [4.3] or more 100 ~ 245 (1.0 ~ 2.5) [10 ~ 36]

Main pressure ↑ 880 (9.0) [130] or more 980 ~ 1370 (10 ~ 14) [140 ~ 200]

Clutch pressure PT1/8 (SST) ↑ ↑


Section 2.1

kalstatt

Text Box

2.1-32

2-33






Standard: Approx. 1900 rpm

Accelerator pedal


Section 2.1

kalstatt

Text Box

2.1-33

torque converter & transmission

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