2-1

TORQUE CONVERTER & TRANSMISSION

Page
1 SPEED TORQUE 2 STATORS TORQUE
CONVERTER (STD) ..............2-2 CONVERTER (OPT)............ 2-41 0
GENERAL ................................2-2 GENERAL .............................. 2-41 1
HYDRAULIC CIRCUIT HYDRAULIC CIRCUIT 2
DIAGRAM ..............................2-5 DIAGRAM ............................ 2-43
3
SPECIFICATIONS ...................2-6 SPECIFICATIONS ................... 2-44
COMPONENTS .........................2-7 COMPONENTS....................... 2-45 4
TROUBLESHOOTING .............2-18 TROUBLESHOOTING ............. 2-49 5
TRANSMISSION COVER & TORQUE CONVERTER ........... 2-50 6
CONTROL VALVE ASSY ........2-19 TORQUE CONVERTER &
TRANSMISSION ASSY .......... 2-56
7
TORQUE CONVERTER·
OIL PUMP ............................2-23 TRANSMISSION ASSY............ 2-60 8
TORQUE CONVERTER &
TRANSMISSION ASSY ..........2-26
STATOR SHAFT NO.2 & 9
OIL PUMP ASSY................... 2-71
TRANSMISSION ASSY ............2-30 10
CLUTCH DRUM ASSY ............ 2-73
CLUTCH DRUM ASSY .............2-37 11
DIRECTION SWITCH 12
ASSY ................................... 2-76 13
REMOVAL·INSTALLATION ...... 2-76
14
OIL PRESSURE
MEASUREMENT AND 15
STALL TEST 16
(1 SPEED TORQUE
CONVERTER (STD))........... 2-77 17
OIL PRESSURE 18
MEASUREMENT AND
STALL TEST 19
(2 STATORS TORQUE 20
CONVERTER (OPT))........... 2-79
21
E
2-2

1 SPEED TORQUE CONVERTER (STD)

GENERAL
Torque Converter

R F

F: Forward
R: Reverse
 2-3

Control Valve (Upper)

0
1
2
A A
3
B B
4
5
6
C C
7
8
9
10
11
12
A-A: Regulator valve
13
14
15
16
B-B: Inching valve
17
18
19
C-C: Accumulator
20
21
E
2-4

Control Valve (Lower)

A A

B B

C C

A-A: Safety valve

B-B: Shift change valve (R)

C-C: Shift change valve (F)

 Inching valve

Solenoid valve (R)

Shift change valve (R)

Accumulator
HYDRAULIC CIRCUIT DIAGRAM

Solenoid
Safety valve valve (F)

Regulator valve

Relief
valve

In-line strainer

Oil pump

R clutch Cooler
Shift change valve (F)

F clutch
Oil
filter
2-5

9
8
7
6
5
4
3
2
1
0

E
11

21
20
19
18
17
16
15
14
13
12
10
2-6

SPECIFICATIONS
Item 1 speed torque converter
Maker Aisin
Torque converter type 3 elements, 1 stage, 2 phases type
4Y·1DZ-III 2.68
Stall torque ratio
3Z 2.61
4Y·1DZ-III 2200
Stall speed rpm
3Z 2050
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) 6.0 (1.58)
Torque converter oil ATF GM Dexron® II

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

Torque Converter Gear Ratio

Torque Converter Ratio
Vehicle model Engine
Forward Reverse
1 ton series 4Y·1DZ-III 1.633 1.641
K2 ton series 4Y·1DZ-III ↑ ↑
4Y·1DZ-III ↑ ↑
2 ton series
3Z 1.323 1.341
1DZ-III 1.633 1.641
3 ton series
4Y·3Z 1.323 1.341
4Y ↑ ↑
J3.5 ton series
3Z ↑ ↑
 2-7

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

3201

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

3201
2-8

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

3201

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

3201
 2-9

Torque Converter Housing (3Z Engine Vehicle, Dry Brake Model (STD))

3201

Torque Converter Housing (3Z Engine Vehicle, Wet Brake Model (OPT))

3201
2-10

4Y Engine Vehicle

3202

1DZ-III, 3Z Engine Vehicle

3202
 2-11

Torque Converter Clutch

3203

Torque Converter Gear

3204

Refer to
FIG.3203

41A

42 AZ

41

45A
46
AP 45
42A
AD
75B

45B

BA

3204-085
2-12

Control Valve

3206

3206
10

CC
PD
AF

AK
AD AB

AL

50
KB
DF 54
BG 51
DY DW
AT
44
HH
HF
BG
BG HV
BX
AT BG
CJ
AT

3206-128
 2-13

3206

Torque Converter Piping (1DZ-III Engine Vehicle, Dry Brake Model (STD))

3213
2-14

Torque Converter Piping (1DZ-III Engine Vehicle, Wet Brake Model (OPT))

3213

Torque Converter Piping (3Z Engine Vehicle)

3213
 2-15

Torque Converter Piping (4Y Engine Vehicle)

3213

Torque Converter Piping (4Y Engine Vehicle, 2·K2·3·J3.5 ton series, Cooler)

3213
2-16

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

3213

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

3213
 2-17

Direction Switch

5701
 Disassembly and inspection
2-18

Components other than control valves On-board inspection

Control valve (torque converter & transmission)

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
Relief valve
Wire to solenoid
Oil strainer
Torque converter
Oil pump
Clutch drum for F
Clutch drum for R
Gear, bearing
Shift lever switch and
neutral start switch
ATF level and quality
Inching lever, and
wire cable
Oil pressure test
Stall test
TROUBLESHOOTING

Faulty starting No starting at F

No starting at R

No starting at any ranges

No starting at N

Large shock at At N F
starting (shifting)
At N R

after shifting
At N

start
Inching At starting
At R

Large time lag at At N F

starting (shifting)
At N R

At switch back F R

Slippage At F

At R

Others Starter fails to revolve at N.

Starter revolve at ranges other than N.

No inching operation

Overheating of transmission,
no air flow from breather

Abnormal noise
 2-19

TRANSMISSION COVER & CONTROL VALVE ASSY

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

T = 21.0 (214) [15.5]

Removal Procedure
1 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 Procedure
The installation procedure is reverse of the removal procedure.
2-20

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

T = 12.5 (127) [9.2]

3

T = 21.0 (214) [15.5] 5

4
T = 7.9 (81)
[5.8]
3

2
7

T = 20.2 (206) [14.9]

T = 7.9 (81) [5.8]

Disassembly Procedure
1 Disconnect the solenoid valve connector.
2 Remove the solenoid valve.
3 Remove the sleeve lock plate and solenoid wire ASSY.
4 Remove the inching lever.
5 Remove the inching 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 Procedure
The reassembly procedure is reverse of the disassembly procedure.
 2-21

Point Operations
[Point 1]
Reassembly:
SST(2)
SST 09950-76018-71................................. (1)
SST(1) (09950-60010)
09950-76020-71................................. (2)
(09950-70010)

[Point 2]
Service bolt Disassembly:
Remove the accumulator valve plug using the service bolt.
Service bolt size: M8×1.25

Inspection:
Measure free length of each valve spring.

Standard mm (in) Limit mm (in)

Inner 67.4 (3.390) 64.0 (3.220)
Accumulator valve
Outer 127.8 (5.031) 121.4 (4.780)
Plug side 64.2 (2.528) 61.0 (2.402)
Inching valve
Valve side 49.9 (1.965) 47.4 (1.866)
Regulator valve 132.4 (5.213) 125.8 (4.953)

[Point 3]
Reassembly:
Install the lower valve body.
1. Install the oil strainer, spring and relief valve piston on the
lower valve body, and put the gasket on top.
2. Reverse the above while maintaining the assembled state and
install it on the transmission cover.
2-22

[Point 4]
Disassembly:
Press in the valve plug with its opening facing downwards and
remove the key.

Inspection:
Measure free length of each valve spring.
Standard mm (in) Limit mm (in)
F/R shift valve 59.8 (2.354) 56.8 (2.236)
Safety valve 59.8 (2.354) 56.8 (2.236)
 2-23

TORQUE CONVERTER·OIL PUMP

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

T = 21.0 (220) [15.9]

Removal Procedure
1 Drain torque converter oil.
2 Remove the engine ASSY. (See page 1-10)
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 Procedure
The installation procedure is reverse of the removal procedure.

Point Operations
[Point 1]
Removal:
Be careful as the torque converter ASSY contains oil.
Oil
seals Installation:
Apply MP grease to the seal ring and oil seal lip before
installation.
Installation:
Install while rotating the torque converter ASSY so that the
extension claw engages with the groove in the oil pump drive gear.
2-24

[Point 2]
Service tap
Removal:
SST 09950-76014-71
(09950-40011)

Service tap

SST

Installation:
Be careful not to install the pre-coated bolts in incorrect
positions.
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 and
pump body.
Limit: 0.3 mm (0.012 in)

Inspection:
Measure the clearance between the pump body and each
gear.
Standard: 0.042 ~ 0.080 mm (0.002 ~ 0.003 in)
 2-25

Inspection:
The marks have no meaning for reassembly.

Marks

[Point 5]
Installation:
SST 09370-10410-71
SST
2-26

TORQUE CONVERTER & TRANSMISSION ASSY

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

31 29

26 9

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]
4Y engine vehicle
T = 56.8 ~ 64.7 (580 ~ 660) [42.0 ~ 47.8]
Drive plate set bolt (for connecting to engine crankshaft)
1DZ-III, 3Z engine vehicle
T = 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]
 2-27

Removal Procedure
1 Remove the engine hood. (Refer to page 9-10)
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-III, 3Z engine vehicle)
7 Disconnect the accelerator wire. (1DZ-III, 3Z 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 8-64)
24 Remove the brake cooling oil tank. (Wet Brake model) (Refer to page 8-63)
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 3-5, Wet Brake model: Refer to page 3-6)
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.
2-28

Installation Procedure
The installation procedure is the reverse of the removal procedure.
Note:
After installing the engine ASSY, perform air bleeding of the fuel system. (1DZ-III, 3Z engine vehicle) (Refer to
page 1-13)

Point Operations
[Point 1]
Removal:
Put match marks on the transmission case and torque
converter cooler hose.

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

SST(1) [Point 3]
SST(2) Removal•Installation:
SST 09010-20111-71 ................................. (1)
09010-23320-71................................. (2)

[Point 4]
Removal•Installation:
SST Move the SST hook position to adjust the balance.
 2-29

[Point 5]
Removal•Installation:
Turn the flywheel using the crankshaft pulley set bolt.

Crankshaft
pulley set bolt
2-30

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

T = 56.0 (571) 16
[41.3]
17
T = 12.7 (129.5)
[9.4]
14 10

14
14
9
8

11
7

T = 69.0 ~ 96.0
T = 19.0 (193.7) [14.0] (703.6 ~ 978.9) 13
[50.9 ~ 70.8] 15
14
12
4

14 6
T = 21.0 (214.1) [15.5]

3
T = 35.0 (357)
[25.8]

T = 32 ~ 48 T = 56.0
(326.3 ~ 489.5) (571.0)
[23.6 ~ 35.4] [41.3]
 2-31

Disassembly Procedure
1 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 & forward
clutch drum ASSY. [Point 6]
(Refer to page 2-37 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 Procedure
The reassembly procedure is the reverse of the disassembly procedure.

Point Operations
Service tap
[Point 1]
Disassembly:
SST 09950-76014-71
(09950-40011)
Service tap

SST

Reassembly:
Be careful not to install the pre-coated bolts in incorrect
positions.
Reassembly:
When reusing precoated bolts, apply thread tightener (08833-
76002-71 (08833-00080)) to the threaded part.
2-32

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 the
main shaft gear system.
A
Standard: A = 0.10 ~ 0.24 mm (0.004 ~ 0.009 in)

2. If the standard is not satisfied, increase or decrease the shim

Shim thickness for adjustment.
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)

[Point 2]
Disassembly:
Insert a flat head screwdriver in the cut portion of the rear case
and remove the case.

Magnet Reassembly:
Assemble after removing iron powder staying on the magnet.
 2-33

[Point 3]
Reassembly:
Adjust the output gear thrust clearance.
1. Temporarily install the output gear, shim and rear case, and
measure the output gear thrust clearance.
Standard: A = 0.10 ~ 0.49 mm (0.004 ~ 0.019 in)
A

Shim 2. If the standard is not satisfied, increase or decrease the shim

thickness for adjustment.
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)

[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)

Shim
2. If the standard is not satisfied, increase or decrease the shim
thickness for adjustment.
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)

[Point 5]
Disassembly•Reassembly:
Disassemble or reassemble the counter gear shaft together
with the main shaft ASSY.
2-34

[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 or
the like, reassemble the clutch gear.

[Point 7]
Disassembly:
SST 09950-76018-71................................. (1)
(09950-60010)
SST(2) 09950-76020-71................................. (2)
(09950-70010)

SST(1)

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

[Point 8]
Disassembly:
SST 09950-76018-71................................. (1)
(09950-60010)
SST(2)
09950-76020-71................................. (2)
(09950-70010)
SST(1)
 2-35

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

SST(1)

[Point 9]
Disassembly•Reassembly:
SST 09905-76002-71
(09905-00012)

SST

[Point 10]
Reassembly:
SST 09370-20270-71

SST

[Point 11]
Disassembly:

SST SST 09320-23000-71

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

SST(1)
2-36

[Point 12]
Disassembly•Reassembly:
Use a flat head screwdriver or the like to disassemble or
reassemble the output shaft oil seal.
Reassembly:
A Reassemble the output shaft oil seal to the position A in the
illustration.
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, and
remove the oil strainer.

[Point 14]
Disassembly•Reassembly:
SST 09228-76004-71
(09228-07501)

SST

Clutch operation check after reassembly

F
R Blow air through the oil hole on top of the transmission case and
check that each clutch piston operates normally.

F R
 2-37

CLUTCH DRUM ASSY

DISASSEMBLY·INSPECTION·REASSEMBLY

Disassembly Procedure
1 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 Procedure
The 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)
2-38

Inspection:
Measure thickness of the clutch plate.
Standard: 2.0 mm (0.079 in)
Limit: 1.8 mm (0.071 in)

Inspection:
Measure height of the camber plate curving.
Standard: 3.4 mm (0.134 in)
Limit: 3.1 mm (0.122 in)

Reassembly:
Clutch gear side
Reassemble with the punched side facing upwards (the clutch
gear side).

Piston side
Punching
 2-39

Reassembly:
Install the clutch plates and clutch discs alternately on the
clutch drum while applying torque converter oil.
Number of clutch discs
1 ton series 4Y·1DZ-III models 4
K2 ton series 4Y·1DZ-III models 5
4Y·1DZ-III models 5
Camber plate 2·3 ton series
3Z model 5
4Y model 5
J3.5 ton series
3Z model 5

Reassembly:
Adjust the clearance between the backing plate and clutch
disc.
1. Install the camber plate, clutch plates, clutch discs, backing
plate and snap ring on the clutch drum.
2. Measure clearance between the backing plate and snap ring
using 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 a

Identifying grooves suitable backing plate.
Backing plate thickness
A Identifying grooves

A 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 Reassembly:

Install the backing plate with its stepped side (with groove)
facing upward (on the clutch gear side).
2-40

[Point 2]
Disassembly•Reassembly:
SST(1) Compress the return spring using the SST and remove or
install the snap ring.
SST(2) Tie two hooks of the SST using a wire or string as shown in the
illustration to fix it in the clutch drum.
SST 09220-22001-71................................. (1)
09905-76002-71................................. (2)
(09905-00012)
Wire

Caution:
The hooks may come off the clutch drum and spring may jump
out when using the SST. Be careful not to allow the hooks to
come 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-between
and remove the piston.
Reassembly:
Apply torque converter oil on the piston ring and seal ring, and
assemble the clutch piston.
 2-41

2 STATORS TORQUE CONVERTER (OPT)

GENERAL

F: Forward
R: Reverse
2-42

Control Valve

Inching valve

A-A

Regulator valve
Accumulator
 Main pressure port
PT1/8"

Main pressure
Regulator valve Accumulator orifice

Regulator Accumulator
orifice
Oil cooler
Orifice
Inching valve
HYDRAULIC CIRCUIT DIAGRAM

Forward clutch Oil filter Coin filter

Lubrication
F
F/R solenoid valve
Reverse
pressure port
Forward PT1/8"
pressure port Sol (2) Sol (1)
PT1/8" F
R
R

Reverse clutch Sol (1) Sol (2)

Torque converter
F ON OFF
Suction filter
R OFF ON

N OFF OFF
2-43
2-44

SPECIFICATIONS
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
Forward 1.041
Torque converter gear ratio
Reverse 1.041
Control system Solenoid type selector valve
Clutch operating pressure (main pressure) 2) 1000 ~ 1400 (10.2 ~ 14.2) [145 ~ 203]
kPa (kgf/cm [psi]
Torque converter outlet pressure kPa (kgf/cm2) [psi] 100 ~ 400 (1.02 ~ 4.1) [14.5 ~ 58]
Torque converter oil capacity l (USgal) 10.0 (2.64)
Torque converter oil ATF GM Dexron® II

Note:
The indicated oil pressure is at an engine speed of 1500 rpm.
 2-45

COMPONENTS
Torque Converter Housing

3201
AC BV
22
30 AB AC BV

44

45B

AI

45C

BU

EP 25A EV
BA

AO
25

3201-240

Torque Converter

3202
AD
25 EF

BL 25A

28 EU
28A

AZ

56E

21
CP
22C

56A
22
56B 56
22F
46D 22B
46E
46C
BP
54
46
29 52
46B 53
46A
BQ
CR

66 32A
26
45
45B 32
45A
45C 23
24
AA
AM 30
11
3202-102
2-46

Torque Converter Clutch

3203

45
24A
24 24A

45A 24L 24D

25H
45D 22A 25D
57 22
25
43
57A AJ 25H
AQ CN 25C
10
24B 40 22A
41 22
40
41
40 43
41 AJ
40 CN
41 11
40
41 40
40 41
41 40
40 41
41 40
40 41
41 40
40 41
40 46
50
42 41
42A 40
41
40
41
40 46A
41
40
50 58 46B
42
42A

64 AT

25E

3203-141

Torque Converter Gear

3204

Refer to
3203-10
44C
Refer to 43C
3203-11 44A

44

43

66
46
66A

66B

AO
AP
AK
66C

3204-086
 2-47

Control Valve

3206

44C
BW
31 AW
32

GN
CY
EH
EF
CX CG 31
BC JF RO
BB

CJ 41
ED CB
EQ
51 GW
DJ
DI

50
AV
EA
BX
3206-131

Torque Converter Piping

3213

AT

10

HU

30A
HT

30

3213-161
2-48

Direction Switch

5701
 Inspection after disassembly
Other then control valves Inspection on the vehicle
Control valves
(torque converter & transmission)
TROUBLESHOOTING

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

The vehicle does not move when F is selected. { { { { {

The vehicle does not move when R is selected. { { { { {
Starting defect
The vehicle does not move for any range selection. { { { { { { { { { { {
The vehicle moves regardless of N selection. { { { {

Starting N→F { { { {
Excessive shock (shifting) N→R { { { {
upon starting
(shifting). Starting At F { { { { { {
(inching) At R { { { { { {
N→F { { { { { { { {
Excessive time lag
upon starting N→R { { { { { { { {
(shifting)
Upon switch-back F ↔ R { { { { { { { {
At F { { { { { { {
Slipping
At R { { { { { { {
The starting motor does not run at N. {
The starting motor runs at other than N. {
Inching operation fails. { { { {
Others
Transmission overheating or oil spouting from
{ { { { { { {
breather.
Abnormal noise. { { { {
2-49
2-50

TORQUE CONVERTER
REMOVAL·INSTALLATION
T = N·m (kgf·cm) [ft·lbf]

Removal Procedure
1 Drain torque converter oil.
2 Remove the engine ASSY. (See page 1-10)
3 Remove the torque converter.

Installation Procedure
The installation procedure is reverse of the removal procedure.
 2-51

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

6 3

T = 18.6 ~ 24.5
5
(190 ~ 250)
[13.1 ~ 18.1]

2
2

Disassembly Procedure
1 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 Procedure
The reassembly procedure is reverse of the disassembly procedure.
2-52

Point Operations
Match mark [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)
SST (2)
09950-76020-71................................. (2)
(09950-70010)
SST (1)

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

SST (2)

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)
 2-53

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 and
spring 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 them
with tweezers or a similar tool.

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

2-54

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

direction.

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

Hold

Turning
direction

Thrust
[Point 4]
bearing Reassembly:
Never install the one-way clutch, thrust bearing and stator hub
in wrong directions. (See the illustration)

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

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

Turning
direction

[Point 5]
Disassembly:

SST SST 09320-23000-71

 2-55

Reassembly:
SST 09950-76018-71................................. (1)
SST (2) (09950-60010)
09950-76020-71................................. (2)
(09950-70010)
SST (1)
2-56

TORQUE CONVERTER & TRANSMISSION ASSY

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

31 29

26 9

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]
4Y engine vehicle
T = 56.8 ~ 64.7 (580 ~ 660) [42.0 ~ 47.8]
Drive plate set bolt (for connecting to engine crankshaft)
1DZ-III, 3Z engine vehicle
T = 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]
 2-57

Removal Procedure
1 Remove the engine hood. (Refer to page 9-10)
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-III, 3Z engine vehicle)
7 Disconnect the accelerator wire. (1DZ-III, 3Z 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 8-64)
24 Remove the brake cooling oil tank. (Wet Brake model) (Refer to page 8-63)
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 3-5, Wet Brake model: Refer to page 3-6)
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.
2-58

Installation Procedure
The installation procedure is the reverse of the removal procedure.
Note:
After installing the engine ASSY, perform air bleeding of the fuel system. (1DZ-III, 3Z engine vehicle) (Refer to
page 1-13)

Point Operations
[Point 1]
Removal:
Put match marks on the transmission case and torque
converter cooler hose.

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

SST(1) [Point 3]
SST(2) Removal•Installation:
SST 09010-20111-71 ................................. (1)
09010-23320-71................................. (2)

[Point 4]
Removal•Installation:
SST Move the SST hook position to adjust the balance.
 2-59

[Point 5]
Removal•Installation:
Turn the flywheel using the crankshaft pulley set bolt.

Crankshaft
pulley set bolt
2-60

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

4
6 12
7 10
5
3

11

26

23
9 24
26

26
17 28
29 25
26

27

13 27
14
14
22

21

19 20

16
15

2
18
 2-61

Disassembly Procedure
1 Drain the torque converter oil.
2 Remove the torque converter.
(For disassembly, inspection and reassembly of torque converter ASSY, see page 2-51)
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 2-71) [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 2-73)
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 2-73)
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]
2-62

Reassembly Procedure
The 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 torque
converter case.

Point Operations
[Point 1]
Inspection:
Inspect the solenoid valve for continuity.
2: R (–) 1: R (+) Between 1 and 2: Continuity
Between 3 and 4: Continuity

4: F (–) 3: F (+)

[Point 2]
Inspection:
Measure the free length of the inching valve spring.
mm (in)
Standard Limit
Inner spring 27 (1.06) 24 (0.94)
Outer spring 63.3 (2.49) 58 (2.28)

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

[Point 3]
Inspection:
Inspect and wash the coin filter to eliminate clogging.
 2-63

[Point 4]
Disassembly:
SST 09950-76018-71................................. (1)
SST (2)
(09950-60010)
SST (1) 09950-76020-71................................. (2)
(09950-70010)

[Point 5]
Inspection:
Measure the free length of the accumulator spring.
mm (in)
Standard Limit
Inner spring 70 (2.756) 62 (2.441)
Outer spring 122 (4.803) 108 (4.252)

[Point 6]
Service bolt Disassembly•Reassembly:
Use the service bolt for disassembly and reassembly of the
regulator 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
2-64

[Point 8]
SST Disassembly•Reassembly:
SST 09010-13200-71

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

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

[Point 9]

SST Disassembly:
SST 09950-76014-71
(09950-40011)

Reassembly:
Use a round bar and install the idle gear W/ bearing.
 2-65

[Point 10]
Disassembly:
SST 09950-76018-71................................. (1)
SST (2) (09950-60010)
09950-76020-71................................. (2)
(09950-70010)
SST (1)

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

SST (1)

[Point 11]
Inspection:
Measure the seal ring side clearance.
Limit: 0.3 mm (0.012 in)

[Point 12]
Disassembly:
SST (1)
SST 09950-76014-71................................. (1)
(09950-40011)
09950-76018-71................................. (2)
(09950-60010)
SST (2)

Reassembly:
Use a round bar and install the bearing.
2-66

[Point 13]
Disassembly:
SST SST 09320-23000-71

Reassembly:

SST (1) SST (2) 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 pump
ASSY.

[Point 15]
SST Disassembly:
SST 09950-76014-71
(09950-40011)

Reassembly:
SST (2) SST 09950-76019-71................................. (1)
(09950-60020)
SST (1) 09950-76020-71................................. (2)
(09950-70010)
 2-67

[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.

A [Point 18]
Reassembly:
Install the bearing in the correct direction (See the illustration.)

A>B
B

[Point 19]
Disassembly:
Remove the output shaft ASSY by tapping its tip end with a
plastic hammer.
2-68

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

[Point 20]
Inspection:
Measure the side clearance of each shaft seal ring.
mm (in)
Limit
Main shaft 0.3 (0.012)
Reverse shaft 0.3 (0.012)

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

SST

Reassembly:
Use a round bar and install the bearing.
 2-69

[Point 21]
Disassembly:
Remove the clutch gear W/ bearing using the SST and a
press.
SST SST 09420-23002-71

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

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

Reassembly:
Plate
1. Insert a plate between the clutch gear and clutch drum as
illustrated, and temporarily install the gear first.
2. Use a round bar and install the clutch gear bearing to the
clutch gear.
3. Remove the plate.

[Point 22]
Reassembly:
SST SST 09150-10170-71
2-70

[Point 23]
Disassembly:
SST (2)
SST 09950-76018-71................................. (1)
(09950-60010)
09950-76020-71................................. (2)
(09950-70010)

SST (1)

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

SST (1)
 2-71

STATOR SHAFT NO.2 & OIL PUMP ASSY

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

Disassembly Procedure
1 Remove the stator shaft NO.2. [Point 1]
2 Remove the oil pump gear. [Point 2]
3 Remove the oil seal. [Point 3]

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

Point Operations
[Point 1]
Insert flathead screwdrivers between the stator shaft No. 2 and oil
pump ASSY to separate them.
2-72

Inspection:
Measure the outside diameter of the stator shaft No.2 in sliding
contact 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 and
pump 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 mounting
surface 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
bushing and 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
 2-73

CLUTCH DRUM ASSY

DISASSEMBLY·INSPECTION·REASSEMBLY

Disassembly Procedure
1 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 Procedure
The reassembly procedure is reverse of the disassembly procedure.
2-74

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 and
clutch plate.
Standard:
mm (in)
Standard Limit
Clutch plate 1.6 (0.063) 1.4 (0.055)
Clutch disc 2.6 (0.102) 2.3 (0.091)
Clutch plate Clutch disc

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

Reassembly:
Upward Install the camber plate with the chamfered face facing
upward.

Downward

Reassembly:
A Carefully install each plate in the correct order.
Clearance between snap ring and pressure plate.
Standard: A = 3.1 mm (0.122 in) (Reference)
 2-75

[Point 2]
Disassembly•Reassembly:
SST Use the SST to compress the return spring for snap ring
installation or removal. Bind two hooks of the SST with a wire
or cord as illustrated to prevent departure from the clutch
drum.
SST 09220-33901-71
Caution:
Carefully operate with sufficient check since the hook may
come off from the clutch drum to cause the spring to fly out
while 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)
2-76

DIRECTION SWITCH ASSY

REMOVAL·INSTALLATION

Disassembly Procedure
1 Remove the steering column cover.
2 Disconnect the connector.
3 Remove the direction switch ASSY. [Point 1]

Installation Procedure
The installation procedure is reverse of the removal procedure.

Point Operations
[Point 1]
Inspection:
RH spec. LH spec. Inspect for continuity between the pins of the switch connector.
1: — 1: VR
2: IG2 2: Ra (P:Position, T:Terminal No., :Continuous)
3: N 3: ST
4: IG1 4: VF2 P T N IG1 IG2 VF ST VR Ra
5: VF 5: VF
F1
6: VF2 6: IG1
7: ST 7: N
8: Ra 8: IG2 N
9: VR 9: —
VF : Forward solenoid
VF2 : Forward (F2) solenoid R
VR : Reverse solenoid Rr
ST : Starting motor relay Ra
Ra : Backup lamp & buzzer
 2-77

OIL PRESSURE MEASUREMENT AND

STALL TEST (1 SPEED TORQUE
Front 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.

Back (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 (lower
limit), adjust it to an appropriate level.

Clutch pressure (F) Clutch pressure (R) 3. Measure the oil pressure.
Main
pressure (1) Check and adjust the engine speed.
(2) Stop the engine and jack up at the front axle to raise
wheels (both tires).
(3) Set the oil pressure gauge. (If three oil pressure gauges
are available, measure the main, clutch and torque
converter outlet pressures at a time.)
Use the adapter (SST) for the main pressure and clutch
pressure detection port.
Outlet pressure
SST 09350-23320-71
(SST thread size: Valve side 5/16 UNF, Oil pressure
gauge side PT1/8)

Use the adapter (SST) for the outlet pressure detection

Wet brake port. (Wet brake model only)
model 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, and
the torque converter outlet pressure at 2000 rpm.
(5) Operate the direction switch to the F and R positions, and
measure the respective clutch working pressures at idle
SST and at 2000 rpm.
Outlet pressure
Note:
Do not step on the inching pedal while measuring oil pressure.
Standard:
kPa (kgf/cm2) [psi]

Detecting pressure Plug size Idle 2000 rpm

735 ~ 1324 (7.5 ~ 13.5)
Main pressure PT1/8 (SST) 890 ~ 1270 (9.1 ~ 13.0) [129 ~ 185]
[106.6 ~ 192.0]
Clutch pressure ↑ ↑ 890 ~ 1270 (9.1 ~ 13.0) [129 ~ 185]
Torque converter outlet
PT1/8 — 80 ~ 540 (0.8 ~ 5.5) [11.3 ~ 78.2]
pressure
2-78

4. Carry out the stall test.

(1) Load cargo having near the permissible maximum load,
firmly set stoppers at the front and rear wheels, and
activate the parking brake.
Caution:
Prevent the vehicle from moving by pulling at the rear by a
wire as shown, to perform the stall test safely.

(2) Warm up the engine and measure the idle speed, no-load
static maximum revolution and relief down.
(3) Set the direction switch to the forward position, depress
Accelerator pedal the accelerator pedal all the way and measure the stall
speed after the engine speed is stabilized.
Standard:
4Y: Approx. 2200 rpm
1DZ-III: Approx. 2200 rpm
3Z: Approx. 2050 rpm
 2-79

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 (lower
limit), adjust it to an appropriate level.

3. Measure the oil pressure.

Clutch Clutch pressure (R) Main
pressure (F) pressure (1) Check and adjust the engine speed.
(2) Stop the engine and jack up at the front axle to raise
wheels (both tires).
(3) Set the oil pressure gauge. (If three oil pressure gauges
are available, measure the main, clutch and torque
converter outlet pressures at a time.)
Use the adapter (SST) for the outlet pressure detection
Outlet pressure port. (Wet brake model only)
SST 09321-26600-71

(4) Start the engine, set the direction switch to the N position.
Wet brake
Measure the main pressures at idle and 1500 rpm, and
model
the torque converter outlet pressure at 1500 rpm.
(5) Operate the direction switch to the F and R positions, and
measure the respective clutch working pressures at idle
and at 1500 rpm.
Note:
Do not step on the inching pedal while measuring oil pressure.
Outlet pressure SST

Standard:
kPa (kgf/cm2) [psi]

Detecting pressure Plug size Idle 1500 rpm

600 or more (6 or more)
Main pressure PT1/8 1000 ~ 1400 (10.2 ~ 14.2) [145 ~ 203]
[85 or more]
Clutch pressure ↑ ↑ ↑
Torque converter outlet
↑ — 100 ~ 400 (1.02 ~ 4.1) [14.5 ~ 58]
pressure
2-80

4. Carry out the stall test.

(1) Load cargo having near the permissible maximum load,
firmly set stoppers at the front and rear wheels, and
activate the parking brake.
Caution:
Prevent the vehicle from moving by pulling at the rear by a
wire as shown, to perform the stall test safely.

(2) Warm up the engine and measure the idle speed, no-load
static maximum revolution and relief down.
(3) Set the direction switch to the forward position, depress
Accelerator pedal the accelerator pedal all the way and measure the stall
speed after the engine speed is stabilized.
Standard:
4Y: Approx. 1950 rpm
1DZ-III: Approx. 1950 rpm
3Z: Approx. 1950rpm