TORQUE CONVERTER & TRANSMISSION
Transcript of 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
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
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Control Valve (Upper)
A A
B B
C C
A-A: Regulator valve
B-B: Inching valve
C-C: Accumulator
Transmission Pn & Cu2~3 ton series
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)
Transmission Pn & Cu2~3 ton series
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
Transmission Pn & Cu2~3 ton series
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
Transmission Pn & Cu2~3 ton series
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
Transmission Pn & Cu2~3 ton series
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
Transmission Pn & Cu2~3 ton series
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
Transmission Pn & Cu2~3 ton series
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
Transmission Pn & Cu2~3 ton series
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
Transmission Pn & Cu2~3 ton series
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
Transmission Pn & Cu2~3 ton series
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
Transmission Pn & Cu2~3 ton series
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
Transmission Pn & Cu2~3 ton series
Section 2
2-15
Direction Switch
5701
5701-511A
SH
LD
AT
KA
LG
97SJ NT
AI
14
LG
KA
SHAI
LG
QB
A2
Transmission Pn & Cu2~3 ton series
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
Transmission Pn & Cu2~3 ton series
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]
Transmission Pn & Cu2~3 ton series
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
Transmission Pn & Cu2~3 ton series
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)
Transmission Pn & Cu2~3 ton series
Section 2
2-202-20
[Point 4]
Disassembly:Press in the valve plug with its opening facing downwards andremove the key.
Inspection:Measure free length of each valve spring.
Standard mm (in) Limit mm (in)
F/R shift valve 59.8 (2.354) 56.8 (2.236)
Safety valve 59.8 (2.354) 56.8 (2.236)
Transmission Pn & Cu2~3 ton series
Section 2
2-21
TORQUE CONVERTER·OIL PUMP
REMOVAL·INSTALLATIONT = N·m (kgf·cm) [ft·lbf]
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]
Installation ProcedureThe installation procedure is reverse of the removal procedure.
Point Operations[Point 1]
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
Transmission Pn & Cu2~3 ton series
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
Transmission Pn & Cu2~3 ton series
Section 2
2-23
Inspection:The marks have no meaning for reassembly.
[Point 5]
Installation:
SST 09370-10410-71
Marks
SST
Transmission Pn & Cu2~3 ton series
Section 2
2-242-24
TORQUE CONVERTER & TRANSMISSION ASSY
REMOVAL·INSTALLATIONT = N·m (kgf·cm) [ft·lbf]
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
Transmission Pn & Cu2~3 ton series
Section 2
2-25
Removal Procedure1 Remove the engine hood. (Refer to page 9-9)
2 Remove the lower panel.
3 Remove the toe board.
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.
17 Disconnect the inching wire.
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.
Transmission Pn & Cu2~3 ton series
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)
Point Operations[Point 1]
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
Transmission Pn & Cu2~3 ton series
Section 2
2-27
[Point 5]
Removal•Installation:Turn the flywheel using the crankshaft pulley set bolt.
Crankshaft pulley set bolt
Transmission Pn & Cu2~3 ton series
Section 2
2-282-28
TRANSMISSION ASSY
DISASSEMBLY·INSPECTION·REASSEMBLYT = N·m (kgf·cm) [ft·lbf]
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
Transmission Pn & Cu2~3 ton series
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.
Point Operations[Point 1]
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
Transmission Pn & Cu2~3 ton series
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
Transmission Pn & Cu2~3 ton series
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)
2. If the standard is not satisfied, increase or decrease the shimthickness for adjustment.
[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)
2. If the standard is not satisfied, increase or decrease the shimthickness for adjustment.
[Point 5]
Disassembly•Reassembly:Disassemble or reassemble the counter gear shaft togetherwith the main shaft ASSY.
A
Shim
Mark Thickness mm (in)
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
Mark Thickness mm (in)
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)
Transmission Pn & Cu2~3 ton series
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)
Transmission Pn & Cu2~3 ton series
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)
Transmission Pn & Cu2~3 ton series
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]
Disassembly•Reassembly:
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
Transmission Pn & Cu2~3 ton series
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]
Reassembly ProcedureThe reassembly procedure is reverse of the disassembly procedure.
Point Operations[Point 1]
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
Transmission Pn & Cu2~3 ton series
Section 2
2-362-36
Inspection:Measure thickness of the clutch plate.
Standard: 2.0 mm (0.079 in)
Limit: 1.8 mm (0.071 in)
Inspection:Measure height of the camber plate curving.
Standard: 3.4 mm (0.134 in)
Limit: 3.1 mm (0.122 in)
Reassembly:Reassemble with the punched side facing upwards (the clutchgear side).
PunchingPiston side
Clutch gear side
Transmission Pn & Cu2~3 ton series
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
Transmission Pn & Cu2~3 ton series
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.
Standard: 63.4 mm (2.496 in)
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)
Transmission Pn & Cu2~3 ton series
Section 2
2-39
2 STATORS TORQUE CONVERTER (OPT)
GENERAL
F: ForwardR: Reverse
R
F
Transmission Pn & Cu2~3 ton series
Section 2
2-402-40
Control Valve
Inching valve
Regulator valve
Accumulator
A - A
A
A
Transmission Pn & Cu2~3 ton series
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
Transmission Pn & Cu2~3 ton series
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
Stall torque ratio 3.49
Stall speed rpm 1950
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)
Torque converter oil ATF GM Dexron® II
Transmission Pn & Cu2~3 ton series
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
Transmission Pn & Cu2~3 ton series
Section 2
2-442-44
Torque Converter Clutch
Torque Converter Gear
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
Transmission Pn & Cu2~3 ton series
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
Transmission Pn & Cu2~3 ton series
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
Transmission Pn & Cu2~3 ton series
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.
Transmission Pn & Cu2~3 ton series
Section 2
2-482-48
TORQUE CONVERTER
REMOVAL·INSTALLATIONT = N·m (kgf·cm) [ft·lbf]
Removal Procedure1 Drain torque converter oil.
2 Remove the engine ASSY. (See page 1-8)
3 Remove the torque converter.
Installation ProcedureThe installation procedure is reverse of the removal procedure.
3
Transmission Pn & Cu2~3 ton series
Section 2
2-49
DISASSEMBLY·INSPECTION·REASSEMBLYT = N·m (kgf·cm) [ft·lbf]
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]
Reassembly ProcedureThe reassembly procedure is reverse of the disassembly procedure.
1
1
2
2
3
4
5
6
T = 18.6 ~ 24.5
(190 ~ 250)
[13.1 ~ 18.1]
Transmission Pn & Cu2~3 ton series
Section 2
2-502-50
Point Operations[Point 1]
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.
Standard: 70.00 mm (2.7559 in)
Limit: 69.85 mm (2.7450 in)
Inspection:Measure the seal ring side clearance.
Limit: 0.3 mm (0.012 in)
Match mark
SST (1)
SST (2)
SST (2)
SST (1)
Transmission Pn & Cu2~3 ton series
Section 2
2-51
Inspection:Measure the seal ring side clearance.
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.
Standard: 8.2 mm (0.323 in)
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.
Transmission Pn & Cu2~3 ton series
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
Transmission Pn & Cu2~3 ton series
Section 2
2-53
Reassembly:
SST 09950-76018-71................................. (1)(09950-60010)09950-76020-71................................. (2)(09950-70010)
SST (1)
SST (2)
Transmission Pn & Cu2~3 ton series
Section 2
2-542-54
TORQUE CONVERTER & TRANSMISSION ASSY
REMOVAL·INSTALLATIONT = N·m (kgf·cm) [ft·lbf]
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]
28 26
823
Transmission Pn & Cu2~3 ton series
Section 2
2-55
Removal Procedure1 Remove the engine hood. (Refer to page 9-9)
2 Remove the lower panel.
3 Remove the toe board.
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.
17 Disconnect the inching wire.
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.
Transmission Pn & Cu2~3 ton series
Section 2
2-562-56
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)
Point Operations[Point 1]
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
Transmission Pn & Cu2~3 ton series
Section 2
2-57
[Point 5]
Removal•Installation:Turn the flywheel using the crankshaft pulley set bolt.
Crankshaft pulley set bolt
Transmission Pn & Cu2~3 ton series
Section 2
2-582-58
TRANSMISSION ASSY
DISASSEMBLY·INSPECTION·REASSEMBLYT = N·m (kgf·cm) [ft·lbf]
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
Transmission Pn & Cu2~3 ton series
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]
10 Remove the oil filter. [Point 7]
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]
Transmission Pn & Cu2~3 ton series
Section 2
2-602-60
Reassembly ProcedureThe reassembly procedure is the reverse of the disassembly procedure.
Note:Apply sealing agent (08826-76001-71 (08826-00080)) on the oil strainer surface to be mounted on the torqueconverter case.
Point Operations[Point 1]
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)
Transmission Pn & Cu2~3 ton series
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]
Disassembly•Reassembly:
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
Transmission Pn & Cu2~3 ton series
Section 2
2-622-62
[Point 8]
Disassembly•Reassembly:
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
Transmission Pn & Cu2~3 ton series
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]
Inspection:Measure the seal ring side clearance.
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)
Transmission Pn & Cu2~3 ton series
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)
Transmission Pn & Cu2~3 ton series
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
Transmission Pn & Cu2~3 ton series
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
Transmission Pn & Cu2~3 ton series
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
Transmission Pn & Cu2~3 ton series
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)
Transmission Pn & Cu2~3 ton series
Section 2
2-69
STATOR SHAFT NO.2 & OIL PUMP ASSY
DISASSEMBLY·INSPECTION·REASSEMBLYT = N·m (kgf·cm) [ft·lbf]
Disassembly Procedure1 Remove the stator shaft NO.2. [Point 1]
2 Remove the oil pump gear. [Point 2]
3 Remove the oil seal. [Point 3]
Reassembly ProcedureThe reassembly procedure is the reverse of the disassembly procedure.
Point Operations[Point 1]Insert flathead screwdrivers between the stator shaft No. 2 and oilpump ASSY to separate them.
2
1
3
Transmission Pn & Cu2~3 ton series
Section 2
2-702-70
Inspection:Measure the outside diameter of the stator shaft No.2 in slidingcontact with the pump drive gear.
Standard: 48 mm (1.889 in)
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
Transmission Pn & Cu2~3 ton series
Section 2
2-71
CLUTCH DRUM ASSY
DISASSEMBLY·INSPECTION·REASSEMBLY
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]
Reassembly ProcedureThe reassembly procedure is reverse of the disassembly procedure.
1
2
3
4
Transmission Pn & Cu2~3 ton series
Section 2
2-722-72
Point Operations[Point 1]
Inspection:Measure the camber plate warp height.
Standard: 3.8 mm (0.150 in)
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
Transmission Pn & Cu2~3 ton series
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.
Standard: 100 mm (3.94 in)
Limit: 90 mm (3.54 in)
[Point 3]Inspection:
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
Transmission Pn & Cu2~3 ton series
Section 2
2-742-74
DIRECTION SWITCH ASSY
REMOVAL·INSTALLATION
Disassembly Procedure1 Remove the steering column cover.
2 Disconnect the connector.
3 Remove the direction switch ASSY. [Point 1]
Installation ProcedureThe installation procedure is reverse of the removal procedure.
Point Operations[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)
Transmission Pn & Cu2~3 ton series
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]
Transmission Pn & Cu2~3 ton series
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
Transmission Pn & Cu2~3 ton series
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
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 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.
Note:Do not step on the inching pedal while measuring oil pressure.
Standard:kPa (kgf/cm2) [psi]
Clutch pressure (F)
Clutch pressure (R) Main pressure
Outlet pressure
SST
Wet brake
model
Outlet pressure
Detecting pressure Plug size Idle 1500 rpm
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]
Transmission Pn & Cu2~3 ton series
Section 2
2-782-78
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. 1950 rpm1DZ-II: Approx. 1950 rpm
Accelerator pedal
Transmission Pn & Cu2~3 ton series
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
2-22-2
GENERAL
F: F
orw
ard
R: R
ever
se
RF
Transmission Cu1 ton series
Section 2.1
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)
Transmission Cu1 ton series
Section 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
Transmission Cu1 ton series
Section 2.1
2-5
0123456789101112131415161718192021E
SPECIFICATIONSManufacturer EXEDY
Torque converter type 3-element, 1-stage, 2-phase
Stall torque ratio 2.7
Stall speed rpm 1900
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
kPa (kgf/cm2) [psi] At 2000 rpm 980 ~ 1370 (10 ~ 14) [140 ~ 200]
Torque converter inlet pressure At idling 147 ~ 290 (1.5 ~ 3) [21 ~ 40]
kPa (kgf/cm2) [psi] At 2000 rpm 390 ~ 690 (4 ~ 7) [60 ~ 100]
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)
Torque converter oil ATF GM Dexron® II
Transmission Cu1 ton series
Section 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
Transmission Cu1 ton series
Section 2.1
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
Transmission Cu1 ton series
Section 2.1
2-82-8
Torque Converter Clutch
3202
3203
3202-098
01
AA
EG22
24
23
30
AX
AH
EH
11
Transmission Cu1 ton series
Section 2.1
2-9
Torque Converter Gear
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
Transmission Cu1 ton series
Section 2.1
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
Transmission Cu1 ton series
Section 2.1
2-11
Direction Switch
5701
5701-511A
SH
LD
AT
KA
LG
97SJ NT
AI
14
LG
KA
SHAI
LG
QB
A2
Transmission Cu1 ton series
Section 2.1
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
Transmission Cu1 ton series
Section 2.1
2-13
CONTROL VALVE ASSY
REMOVAL·INSTALLATIONT = N·m (kgf·cm) [ft·lbf]
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.
Installation ProcedureThe installation procedure is reverse of the removal procedure.
4
2
T = 31.4 ~ 37.2(320 ~ 380)[23.2 ~ 27.5]
*: It is unnecessary to remove this bolt here.
3*
Transmission Cu1 ton series
Section 2.1
2-142-14
DISASSEMBLY·INSPECTION·REASSEMBLYT = N·m (kgf·cm) [ft·lbf]
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]
10 Remove the oil seal. [Point 8]
Reassembly ProcedureThe reassembly procedure is reverse of the disassembly procedure.
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
Transmission Cu1 ton series
Section 2.1
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.
Inspection:Measure free length of each valve spring.
[Point 3]Inspection:
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
Standard mm (in) Limit mm (in)
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)
Transmission Cu1 ton series
Section 2.1
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.
[Point 4]Inspection:
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.)
[Point 5]Inspection:
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]
[Point 6]Inspection:
Inspect and wash the coin filter to eliminate clogging.
→
→
→
Groove
→
Groove
Transmission Cu1 ton series
Section 2.1
2-17
Reassembly:Install the coil filter with its chamfered side facing down.
[Point 7]Inspection:
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)
Transmission Cu1 ton series
Section 2.1
2-182-18
TORQUE CONVERTER·OIL PUMP
REMOVAL·INSTALLATIONT = N·m (kgf·cm) [ft·lbf]
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]
7 Remove the oil seal. [Point 3]
Installation ProcedureThe installation procedure is reverse of the removal procedure.
3
4
T = 20.6 ~ 25.5 (210 ~ 260)[15.2 ~ 18.8]
Transmission Cu1 ton series
Section 2.1
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)
[Point 2]Inspection:
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)
Transmission Cu1 ton series
Section 2.1
2-202-20
TORQUE CONVERTER & TRANSMISSION ASSY
REMOVAL·INSTALLATIONT = N·m (kgf·cm) [ft·lbf]
Engine mounting nut T = 53.9 ~ 99.0 (550 ~ 1010) [39.8 ~ 73.1]
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]
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) T = 56.8 ~ 64.7 (580 ~ 660) [42.0 ~ 47.8]
Drive plate set bolt (for connecting to torque converter) T = 14.7 ~ 21.6 (150 ~ 220) [10.9 ~ 15.9]
10
145
Transmission Cu1 ton series
Section 2.1
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.
6 Disconnect the inching wire.
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.
Installation ProcedureThe installation procedure is the reverse of the removal procedure.
Transmission Cu1 ton series
Section 2.1
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.
[Point 4]Removal•Installation:
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)
Transmission Cu1 ton series
Section 2.1
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
[Point 8]Removal•Installation:
Rotate the drive plate by using a crankshaft pulley set bolt.
Transmission Cu1 ton series
Section 2.1
2-242-24
TRANSMISSION ASSY
DISASSEMBLY·INSPECTION·REASSEMBLYT = N·m (kgf·cm) [ft·lbf]
Disassembly Procedure1 Remove the control valve ASSY.
2 Remove the torque converter.
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.
10 Remove the oil filter. [Point 4]
Reassembly ProcedureThe reassembly procedure is reverse of the disassembly procedure.
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
Transmission Cu1 ton series
Section 2.1
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)
[Point 2]Disassembly:
SST 09320-23000-71
Reassembly:SST 09950-76019-71................................. (1)
(09950-60020)09950-76020-71................................. (2)(09950-70010)
[Point 3]Disassembly:
Remove the cover slowly. Otherwise, the spring may jump out.
SST
SST (2) SST (1)
SST
SST (2) SST (1)
Transmission Cu1 ton series
Section 2.1
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.
Standard: 123.4 mm (4.858 in)
Limit: 120.8 mm (4.756 in)
Inspection:Measure the free length of the torque converter inlet valvespring.
Standard: 103.4 mm (4.071 in)
Limit: 99.4 mm (3.913 in)
[Point 4]Disassembly•Reassembly:
SST 09228-76004-71(09228-07501)
SST
Transmission Cu1 ton series
Section 2.1
2-27
CLUTCH DRUM ASSY
DISASSEMBLY·INSPECTION·REASSEMBLY
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
Transmission Cu1 ton series
Section 2.1
2-282-28
Reassembly ProcedureThe reassembly procedure is the reverse of the disassembly procedure.
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)
[Point 2]Disassembly:
SST 09950-76014-71(09950-40011)
[Point 3]Disassembly:
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
Transmission Cu1 ton series
Section 2.1
2-29
[Point 4]Inspection:
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
Transmission Cu1 ton series
Section 2.1
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.
Standard: 54.8 mm (2.157 in)
Limit: 51.8 mm (2.039 in)
[Point 6]Inspection:
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
Transmission Cu1 ton series
Section 2.1
2-31
DIRECTION SWITCH ASSY
REMOVAL·INSTALLATION
Disassembly Procedure1 Remove the steering column cover.
2 Disconnect the connector.
3 Remove the direction switch ASSY. [Point 1]
Installation ProcedureThe installation procedure is reverse of the removal procedure.
Point Operations[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)
Transmission Cu1 ton series
Section 2.1
2-322-32
OIL PRESSURE MEASUREMENT AND STALL TEST1. 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. Set the oil pressure gauge.
(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.
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
Note:Do not step on the inching pedal while measuring oil pressure.
Standard:kPa (kgf/cm2) [psi]
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
Detecting pressure Plug size Idle 2000 rpm
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) ↑ ↑
Transmission Cu1 ton series
Section 2.1
2-33
5. 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: Approx. 1900 rpm
Accelerator pedal
Transmission Cu1 ton series
Section 2.1