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DESCRIPTION
General
A240L, A241E, A243L
The A240L, A241E and A243L automatic transaxles are 4-speed transaxles with a lock-up mechanism
developed exclusively for use with a transversely-mounted engine.
The A241E automatic transaxle is an Electronically Controlled Transaxle (hereafter called ECT).
These automatic transaxles have the following features.
The “Super-Flow” torque converter is used to improve the transmission efficiency.
When shifting the transmission, the engine torque is controlled and the clutch hydraulic
pressure in the transmission is electronically controlled to reduce transmission shift shock.
(A241E)
Transaxle control ECU has been integrated with the Engine ECU. (A241E)
These automatic transaxle are mainly composed of the torque converter with lock-up clutch, 4-speed
planetary gear unit, the hydraulic control system and the electronic control system.
To minimize the possibility of incorrect operation of the automatic transaxle, a shift lock mechanism has
also been added.
A240L
Torque Converter,
4-Speed Gear Unit
and Hydraulic Control System
Differential
AT4118
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AX-3
AUTOMATIC TRANSAXLE - Description
A241E
A243L
AT5715
AT5716
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AX-4
AUTOMATIC TRANSAXLE - Description
A241H
The A241H automatic transaxle is a 4-speed automatic transaxle developed for full-time 4WD use.
Its construction is that of the favorably received A240L automatic transaxle.
In addition, a center differential control clutch, which operates in response to driving conditions, has been
incorporated.
The center differential control clutch controls excessive differences in the rotation rates of the front and
rear wheels to provide the most suitable driving conditions.
NOTICE: Special handling methods are necessary for full-time 4WD vehicles during inspection and
maintenance. Instructions concerning these handling methods are given on Corolla Repair Manual
(Pub. No. RM252U) on page IN-8.
A241H
Torque Converter,
4-Speed Gear Unit,
and Hydraulic Control System
Front Differential
Center Differential
Center Differential
Control Clutch Transfer
AT4877
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AX-5
AUTOMATIC TRANSAXLE - Description
General Specifications
ATF
Capacity 7.2 7.7 8.0 8.2
liter (7.6, 6.3) (8.1, 6.8) (8.5, 7.0) (8.7, 7.2)
(US. qts, Imp. qts)
Transaxle Oil
E50, API GL5,
Type SAE 75W-90 or
equivalent
Transfer Oil
Capacity
liter 0.8
(US. qts, Imp. qts) (0.8, 0.7)
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AX-6
AUTOMATIC TRANSAXLE - Operation
OPERATION
Mechanical Operation
OPERATING CONDITIONS
Front Planetary
Rear Planetary Gear Unit
Gear Unit One-W ay
Clutch (F1)
U/D Planetary Gear Unit
AT8498
P Park ON OFF
R Reverse ON OFF
N Neutral ON OFF
1st ON OFF
2nd ON ON
D
3rd OFF ON
1st ON OFF
2 2nd ON ON
3rd*2 OFF ON
1st ON OFF
L
2nd*2 ON ON
*1: A241E only : Operating
*2: Down-Shift only in the the 3rd gear for the 2 range and 2nd gear for the L-range - no up-shift
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AX-7
AUTOMATIC TRANSAXLE - Operation
FUNCTION OF COMPONENTS
Component Function
C1 Forward Clutch Connects input shaft and front planetary ring gear.
C2 Direct Clutch Connects input shaft and front & rear planetary sun gear.
C3 U/D Clutch Connects underdrive sun gear and underdrive planetary carrier.
Prevents front & rear planetary sun gear from turning either clockwise or
B1 2nd Coast Brake counterclockwise.
B3 1st & Reverse Brake Prevents rear planetary carrier from turning either clockwise or counterclockwise.
When B2 is operating, this clutch prevents the front & rear planetary
F1 No. 1 One-Way Clutch sun gear from turning counterclockwise.
F2 No. 2 One-Way Clutch Prevents rear planetary carrier from turning counterclockwise.
F3 U/D One-Way Clutch Prevents underdrive planetary sun gear from turning clockwise.
These gears change the route through which driving force is transmitted in
Planetary Gears accordance with the operation of each clutch and brake in order to increase
or reduce the input and output speed.
Intermediate Shaft
Input Shaft
Ring Gear
Counter Shaft
AT2690
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AX-8
AUTOMATIC TRANSAXLE - Operation
AT3216 AT3220
AT3217 AT3221
AT3218 AT3222
D Range O/D
AT3219
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AX-9
AUTOMATIC TRANSAXLE - Operation
VALVE BODY
VALVE BODY
CONSTRUCTION
The electronic control system can be broadly divided into three groups; the sensors, ECU and actuators.
SENSORS Engine & ECT ECU ACTUATOR
Throttle Position Sensor ESA
IDL Engine
Idling Signal VTA Igniter
Throttle Position Signal
SPD
No. 1 Speed Sensor Transaxle S1 No. 1 Solenoid
Valve
SP2 Control of
No. 2 Speed Sensor Shift Timing
No. 2 Solenoid
P S2 Valve
Pattern Select Switch
OD1
Cruise Control ECU
+B
Battery
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AX-102
AUTOMATIC TRANSAXLE (A240L, A241E, A243L) - Component Parts (Valve Body)
A241E
No. 1 Gasket No. 2 Gasket
A240L, A243L
No. 1 Gasket No. 2 Gasket
AT7901 AT7902
AT7904 AT7903
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AX-103
AUTOMATIC TRANSAXLE (A240L, A241E, A243L) - Component Parts (Valve Body)
AT7983
AT3055
A241E
Install: and finger tighten the nine bolts. (A241E)
HINT: Each bolt length (mm) is indicated in the figure.
AT2588
AT3048
A243L (b) Position a new gasket and plate and then anoth-
er new gasket.
Gasket
Plate
Gasket
AT3047
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AX-104
AUTOMATIC TRANSAXLE (A240L, A241E, A243L) - Component Parts (Valve Body)
A241E
Gasket
Plate
Gasket
AT8032
AT3046
AT2546
AT3058
AT3059
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AX-105
AUTOMATIC TRANSAXLE (A240L, A241E, A243L) - Component Parts (Valve Body)
A241E
(b) Tighten the nineteen bolts in the lower valve body.
(A241E)
Torque: 6.4 N-m (65 kgf-cm, 56 in.-lbf)
AT5725
AT3058
7. INSTALL SOLENOID
(a) Install the new O-rings on the each solenoids.
AT7793
AT3138
AT5724
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AX-106
AUTOMATIC TRANSAXLE (A240L, A241E, A243L) - Component Parts (Differential)
Differential
COMPONENTS
♦ Oil Seal
(For Transaxle Housing)
Outer Race
Speedometer
Drive Gear
Side Bearing
Adjusting Shim ♦ Locking Plate
97 (985, 71)
Side Bearing
DISASSEMBLY OF DIFFERENTIAL
1. REMOVE RING GEAR
Matchmarks (a) Place the matchmarks on the ring gear and differ-
ential case.
AT5731
TA0016
AT8087
AT7984
AT8062
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AX-108
AUTOMATIC TRANSAXLE (A240L, A241E, A243L) - Component Parts (Differential)
AT8061
AT8078
AT8059
(c) Remove the two pinions, two side gears and four
Pinion thrust washers.
Thrust Washer
Side
Gear
AT2980
AT7923
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AX-109
AUTOMATIC TRANSAXLE (A240L, A241E, A243L) - Component Parts (Differential)
AT8487
AT8486
SST
AT8479
ASSEMBLY OF DIFFERENTIAL
1. INSTALL SIDE BEARING OUTER RACE OF TRANS-
AXLE HOUSING
(a) Place the shim onto the transaxle housing.
(b)Using SST and press, press a new outer race
into the transaxle housing.
SST 09350-32014 (09351-32111, 09351-32130)
AT8002
AT8003
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AX-1 10
AUTOMATIC TRANSAXLE (A240L, A241E, A243L) - Component Parts (Differential)
AT8497
AT2980
AT8058
AT8093
AT8075
AT5833
AT2982
AT8044
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AX-1 12
AUTOMATIC TRANSAXLE (A240L, A241E, A243L) - Component Parts (Differential)
AT8484
AT8485
Thickness mm (in.)
2.00 (0.0787) 2.20 (0.0866) 2.40 (0.0945) 2.60 (0.1024) 2.80 (0.1102)
2.05 (0.0807) 2.25 (0.0886) 2.45 (0.0965) 2.65 (0.1043) 2.85 (0.1122)
2.10 (0.0827) 2.30 (0.0906) 2.50 (0.0984) 2.70 (0.1063) 2.90 (0.1142)
TA0074
AT8485
MT0089
Case Side
AT2780
TA0019
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AX-1 14
AUTOMATIC TRANSAXLE (A240L, A241E, A243L) - Component Parts (Differential)
AT8005
AT8004
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AX-1 15
AUTOMATIC TRANSAXLE (A240L, A241E, A243L) - Installation of Component Parts
GENERAL NOTES:
1. The automatic transmission is composed of highly precision-finished parts, necessitating
careful inspection before assembly because even a small nick could case fluid leakage or
affect performance.
2. Before assembling new clutch discs, soak them in automatic transmission fluid for at least
fifteen minutes.
3. Apply automatic transmission fluid on sliding or rotating surfaces of parts before assembly.
4. Use petroleum jelly to keep small parts in their place.
5. Do not use adhesive cements on gaskets and similar parts.
6. When assembling the transmission, sure to use new gaskets and O-rings.
7. Dry all parts with compressed air-never use shop rags.
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AX-1 16
AUTOMATIC TRANSAXLE (A240L, A241E, A243L) - Installation of Component Parts
8. Be sure to install the thrust bearings and races in the correct direction and position.
AT2955
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AX-1 17
AUTOMATIC TRANSAXLE (A240L, A241E, A243L) - Installation of Component Parts
mm (in.)
A B C D E F G H
Outer 37.3 45.0 37.9 43.0 41.8
Front Diameter (1.469) (1.772) (1.492) ← (1.693) (1.646)
Bearing
Race Inner 24.1 28.0 22.0 30.5 30.0
Diameter (0.949) (1.102) (0.866) ← (1.201) (1.181)
AT3065
AT2915
AT2913
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AX-1 18
AUTOMATIC TRANSAXLE (A240L, A241E, A243L) - Installation of Component Parts
A240L, A243L
Only
AT2956
AT2911
AT0593
AT2910
Q00980
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AX-1 19
AUTOMATIC TRANSAXLE (A240L, A241E, A243L) - Installation of Component Parts
Q00981
AT0548
AT0547
8. INSTALL PIN
(a) Using a pin punch and hammer, drive in the pin.
(b) Position the spacer and stake it.
AT2959
AT0545
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AX-120
AUTOMATIC TRANSAXLE (A240L, A241E, A243L) - Installation of Component Parts
AT0544
AT0700
AT0701
AT7931
(b) Insert the parking lock pawl shaft and install the
shaft clamp.
Clamp Groove
AT7890
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AX-121
AUTOMATIC TRANSAXLE (A240L, A241E, A243L) - Installation of Component Parts
AT2962
(c) Place the piston into the bore of the case, facing
the spring seats upward.
(d) Using SST, press in the piston.
SST 09350-32014 (09351-32040)
HINT: Be careful not to damage the O-rings.
(e) Remove SST.
SST
AT2963
AT2888
SST
AT2960
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AX-122
AUTOMATIC TRANSAXLE (A240L, A241E, A243L) - Installation of Component Parts
(c) Place the piston into the case with the cup side
up, being careful not to damage the O-rings.
AT2961
AT2901
AT2900
AT2899
AT7889
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AX-123
AUTOMATIC TRANSAXLE (A240L, A241E, A243L) - Installation of Component Parts
AT2898
AT1292
AT1289
AT0597
AT7987
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AX-124
AUTOMATIC TRANSAXLE (A240L, A241E, A243L) - Installation of Component Parts
AT8482
A241E,
Bearing A240L A243L
AT2896
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AX-125
AUTOMATIC TRANSAXLE (A240L, A241E, A243L) - Installation of Component Parts
AT0601
AT0533
AT8084
AT0603
AT0076
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AX-126
AUTOMATIC TRANSAXLE (A240L, A241E, A243L) - Installation of Component Parts
AT0604
AT0523
AT2892
AT8034
AT8039
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AX-127
AUTOMATIC TRANSAXLE (A240L, A241E, A243L) - Installation of Component Parts
AT5602
A240L, A243L
AT2893
AT0527
AT0526
AT0606
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AX-128
AUTOMATIC TRANSAXLE (A240L, A241E, A243L) - Installation of Component Parts
AT0607
AT5829
(c) Install the outer flange, the flat end facing down-
ward.
AT3139
AT0610
AT7892
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AX-129
AUTOMATIC TRANSAXLE (A240L, A241E, A243L) - Installation of Component Parts
AT0612
(c) Install the rear planetary ring gear into the case.
AT0613
AT0323
AT0614
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AX-130
AUTOMATIC TRANSAXLE (A240L, A241E, A243L) - Installation of Component Parts
AT5704
AT2966
AT0798
AT0618
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AX-131
AUTOMATIC TRANSAXLE (A240L, A241E, A243L) - Installation of Component Parts
AT2967
AT0620
AT7990
AT0621
AT2592
AT7891
AT0626
(b) Align the spline of the hub with the flukes of the
discs and install the hub to the second brake discs.
AT0627
AT8088
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AX-133
AUTOMATIC TRANSAXLE (A240L, A241E, A243L) - Installation of Component Parts
AT8056
AT0628
AT2759
AT0631
Front Race
59. INSTALL FRONT PLANETARY RING GEAR
(a) Coat the races and bearing with petroleum jelly
Rear Race and install them onto the planetary ring gear.
Bearing and races: mm (in.)
Outer diameter Inner diameter
AT2968
HINT: If the planetary ring gear and the other parts are
installed correctly into the case, the end of the bushing
with the ring gear flange will be flush with a shoulder of
the intermediate shaft or under.
AT2023
Front Race
(c) Coat the races and bearing with petroleum jelly and
install them onto the tip of ring gear flange as shown.
Bearing and races: mm (in.)
Outer diameter Inner diameter
AT2969
AT0635
AT2970
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AX-135
AUTOMATIC TRANSAXLE (A240L, A241E, A243L) - Installation of Component Parts
AT0349
AT0350
(d) Mesh the hub with the flukes of the direct clutch
while turning the clutch drum or forward clutch.
HINT: If the flukes of the discs are meshed with the hub
correctly, the end of the bushing with the direct clutch
drum will be flush with the surfaces of the forward
clutch.
Bushing
Thrust Washer
AT1984 AT0381
(e) Place the direct clutch and forward clutch into the
case.
(f) While rotating the forward clutch to mesh the front
planetary ring gear and discs, install them.
AT2971
AT2595
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AX-136
AUTOMATIC TRANSAXLE (A240L, A241E, A243L) - Installation of Component Parts
AT0525
AT8484
AT2766
AT2972
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AX-137
AUTOMATIC TRANSAXLE (A240L, A241E, A243L) - Installation of Component Parts
(c) Place the oil pump through the input shaft, and
align the bolt holes of the pump body with the
transmission case.
(d) Hold the input shaft, and lightly press the oil pump
body to slide the oil seal rings on the stator shaft
through the direct clutch drum.
NOTICE: Do not push on the oil pump strongly, or the
oil seal ring will stick to the direct clutch drum.
AT2973
AT0637
AT2974
AT2870
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AX-138
AUTOMATIC TRANSAXLE (A240L, A241E, A243L) - Installation of Component Parts
(b) Install the spring, piston and cover into the bore.
AT2869
AT2867
AT2865
AT8302
(A240L)
Spring Free length mm (in.) Color
Outer 77.8 (3.063) None
C1
Inner 42.50 (1.6732) None
C2 64.8 (2.551) Yellow
No. 1 35.18 (1.3850) Yellow
B2
No. 2 56.68 (2.2315) Yellow
C3 64.72 (2.5480) Red and Yellow
No. 2
Outer
Inner
No. 1
AT3225
A240L
No. 1 Spring
(B2)
AT3036
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AX-140
AUTOMATIC TRANSAXLE (A240L, A241E, A243L) - Installation of Component Parts
AT5707
AT0643
AT5692
AT7991
AT5616
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AX-141
AUTOMATIC TRANSAXLE (A240L, A241E, A243L) - Installation of Component Parts
AT0108
A241E (e) Install the twelve bolts and wire retainer shown in
the illustration, and hand tighten all the bolts first.
Then tighten them with a torque wrench.
HINT: Each bolt length (mm) is indicated in the illustra-
tion.
Torque: 10 N-m (100 kgf-cm, 7 ft-lbf)
Wire
Retainer
AT3146
A240L, A243L
AT3135
AT2584
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AX-142
AUTOMATIC TRANSAXLE (A240L, A241E, A243L) - Installation of Component Parts
AT2975
AT2855
AT2854
AT2853
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AX-143
AUTOMATIC TRANSAXLE (A240L, A241E, A243L) - Installation of Component Parts
AT2976
AT7992
AT7919
81. (A241E)
INSTALL SPEED SENSOR AND SENSOR ROTOR
(a) Install the sensor adaptor with three bolts.
AT2852
AT7932
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AX-144
AUTOMATIC TRANSAXLE (A240L, A241E, A243L) - Installation of Component Parts
AT5684
AT7926
AT7887
AT5683
AT2852
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AX-145
AUTOMATIC TRANSAXLE (A240L, A241E, A243L) - Installation of Component Parts
Thrust Washer
AT2851
O-Rings
AT2850
AT2848
AT5652
AT5641
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AX-146
AUTOMATIC TRANSAXLE (A240L, A241E, A243L) - Installation of Component Parts
AT5639
AT5730
Groove
AT7762
AT5638
(k) Install the manual shift lever with the washer, and
tighten the nut.
86. INSTALL FILLER TUBE AND TRANSMISSION DIP-
STICK
87. INSTALL TWO OIL COOLER PIPES
AT5637
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AX-147
AUTOMATIC TRANSAXLE (A241H) - Removal of Component Parts
Plate
♦ O-Ring
Parking Rod
Manual Valve Lever
Pin Spring
Manual Valve Lever Shaft Second Coast
Spring Brake Piston
Plate Washer ♦ O-Ring Cover
♦ Oil Seal 7.4 (75, 65 in.-lbf) Snap Ring
Neutral Start Switch
Stopper Manual Shift
Manual Valve Lever
♦ Gasket 6.9 (70, 61 in.-lbf) 130 (130, 9) ♦ O-Ring
Detent Spring Spring
Spring Plate ♦ O-Ring
Spring
Valve Body
Clamp
Piston
♦ Gasket
Oil Strainer ♦ Gasket
Cover
♦ Gasket
Magnet
Oil Tube
Clamp
Bracket
Oil Pan
Drain Plug
♦ Gasket
N-m (kgf-cm, ft-lbf) : Specified torque AT3367
♦ Non-reusable part
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AX-148
AUTOMATIC TRANSAXLE (A241H) - Removal of Component Parts
COMPONENTS (Cont’d)
Second Coast
Oil Pump Brake Band
Forward Clutch
♦ O-Ring
Direct Clutch
Race
Pin
Bearing
Race
Race
Bearing One-W ay Clutch
Snap Ring
Plate Flange
Second Brake
Piston
Disc
Snap Ring
Intermediate Shaft
Second Brake
Drum Seal 25 (250, 18)
Second Brake Apply Gasket
Second Coast
Brake Band Guide
Plate
Flange
COMPONENTS (Cont’d)
Bearing Clamp
Retainer Oil Tube
Oil Seal
Ring
Apply Gasket
Transfer Assembly
Plate Clamp
Transaxle Housing
♦ Gasket Cover
♦ Gasket
29 (300, 22)
♦ Apply Gasket
Drain Plug ♦ O-Ring
♦ Gasket
Thrust Washer 29 (300, 22)
Bearing Under Drive
One-W ay Clutch
Retainer
157 (1,600, 116)
Governor Driven Gear
Thrust Washer ♦ Bearing
♦ Nut See page AX-151 Under Drive Clutch
Plate
Under Drive Input Shaft with
Planetary Gear
Differential Spring
♦ Snap Ring Spring Guide
Plate Sleeve
♦ Apply Gasket Plate
N-m (kgf-cm, ft-lbf) : Specified torque 13 (130, 9)
♦ Non-reusable part AT3366
Precoated part
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AX-150
AUTOMATIC TRANSAXLE (A241H) - Removal of Component Parts
AT8074
AT8069 SST
AT8496
AT8079
AT8042
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AX-151
AUTOMATIC TRANSAXLE (A241H) - Removal of Component Parts
AT8043
AT0501
AT0502
AT8053
AT8045
AKPPHELP.RU Руководство по ремонту АКПП
AX-152
AUTOMATIC TRANSAXLE (A241H) - Removal of Component Parts
O-Ring
AT2850
AT8071
AT8051
AT8057
AT3449
AT2854
AT3428
AT3432
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AX-154
AUTOMATIC TRANSAXLE (A241H) - Removal of Component Parts
AT0653
AT3135
AT3433
AT0108
AT0507
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AX-155
AUTOMATIC TRANSAXLE (A241H) - Removal of Component Parts
AT3114
AT1290
AT2860
A12861
AT3036
AKPPHELP.RU Руководство по ремонту АКПП
AX-156
AUTOMATIC TRANSAXLE (A241H) - Removal of Component Parts
AT3111
AT2863
AT3141
AT2865
AT2866
AKPPHELP.RU Руководство по ремонту АКПП
AX-157
AUTOMATIC TRANSAXLE (A241H) - Removal of Component Parts
AT2867
AT2868
AT2869
AT2870
AAT0352
AT3035
AT8049
AT0651
AT0652
AKPPHELP.RU Руководство по ремонту АКПП
AX-159
AUTOMATIC TRANSAXLE (A241H) - Removal of Component Parts
AT2873
AT3461
AT2875
(b) Remove the bearing and race from the ring gear.
AT0515
AT2876
AKPPHELP.RU Руководство по ремонту АКПП
AX-160
AUTOMATIC TRANSAXLE (A241H) - Removal of Component Parts
AT2877
AT2878
AT0518
AT7891
AT0519
AKPPHELP.RU Руководство по ремонту АКПП
AX-161
AUTOMATIC TRANSAXLE (A241H) - Removal of Component Parts
AT2879
AT2880
AT2859
AT2881
AT2882
AKPPHELP.RU Руководство по ремонту АКПП
AX-162
AUTOMATIC TRANSAXLE (A241H) - Removal of Component Parts
AT2883
AT2884
AT0139
AT2885
AT0324
AKPPHELP.RU Руководство по ремонту АКПП
AX-163
AUTOMATIC TRANSAXLE (A241H) - Removal of Component Parts
AT7892
AT2886
AT2887
AT0521
AT0522
AKPPHELP.RU Руководство по ремонту АКПП
AX-164
AUTOMATIC TRANSAXLE (A241H) - Removal of Component Parts
AT2892
AT0523
Spring Seat
AT0376
AT2888 SST
AT2889
AKPPHELP.RU Руководство по ремонту АКПП
AX-165
AUTOMATIC TRANSAXLE (A241H) - Removal of Component Parts
AT2890
AT2891
AT8077
AT3348
AT0526
AKPPHELP.RU Руководство по ремонту АКПП
AX-166
AUTOMATIC TRANSAXLE (A241H) - Removal of Component Parts
AT0627
AT2893
AT7996
AT2895 AT2894
AT0529
AKPPHELP.RU Руководство по ремонту АКПП
AX-167
AUTOMATIC TRANSAXLE (A241H) - Removal of Component Parts
SST
(c)Using SST to hold the driven gear, remove the
lock nut of the another side.
SST 09330-00021
09350-32014 (09351-32032, 09351-32170)
SST
AT0530 AT0531
SST
AT0532
AT0533
AT2896
AT0535
AKPPHELP.RU Руководство по ремонту АКПП
AX-168
AUTOMATIC TRANSAXLE (A241H) - Removal of Component Parts
AT8072
AT2897
AT7889
AT2898
AKPPHELP.RU Руководство по ремонту АКПП
AX-169
AUTOMATIC TRANSAXLE (A241H) - Removal of Component Parts
AT2899
AT2900
AT2901
AT2902
AT2903
AKPPHELP.RU Руководство по ремонту АКПП
AX-170
AUTOMATIC TRANSAXLE (A241H) - Removal of Component Parts
AT0541
AT8058
AT0543
AT0544
AT2904
AKPPHELP.RU Руководство по ремонту АКПП
AX-171
AUTOMATIC TRANSAXLE (A241H) - Removal of Component Parts
AT8082
AT2905
AT2906
AT0547
(b) Slide out the manual valve shaft and remove the
manual valve lever and washer.
AT0548
AKPPHELP.RU Руководство по ремонту АКПП
AX-172
AUTOMATIC TRANSAXLE (A241H) - Removal of Component Parts
AT2907
AT2908
AT5643
AT2910
SST
AT0555
AKPPHELP.RU Руководство по ремонту АКПП
AX-173
AUTOMATIC TRANSAXLE (A241H) - Removal of Component Parts
AT8073
AT3347
AT3346
AT2915
AKPPHELP.RU Руководство по ремонту АКПП
AX-174
AUTOMATIC TRANSAXLE (A241H) - Removal of Component Parts
AT7994
AT7995
AKPPHELP.RU Руководство по ремонту АКПП
AX-16
AUTOMATIC TRANSAXLE (A240L) - Removal of Component Parts
♦ Gasket
Oil Tube 6.9 (70, 61 in.-lbf)
Oil Strainer
Clamp
♦ Gasket
Oil Pan
Magnet
Bracket ♦ Gasket
Drain Plug
Second Coast
Brake Piston ♦ Gasket
Cover ♦ O-Ring
Spring Spring
♦ O-Ring
Spring
Spring
♦ O-Ring B4 Accumulator Piston
♦ O-Ring Bolt
Accumulator Piston
C3 Accumulator Piston
♦ O-Ring
♦ O-Ring Oil Gallery Cover
Spring
N-m (kgf-cm, ft-lbf) Specified torque ♦ Gasket
♦ Non-reusable part AT5701
Precoated part Cover AT2841
AKPPHELP.RU Руководство по ремонту АКПП
AX-17
AUTOMATIC TRANSAXLE (A240L) - Removal of Component Parts
COMPONENTS (Cont’d)
Sun Gear
Second Coast Input Drum
Brake Band
Bearing Race
Bearing
Thrust Washer Front Planetary
Pin Gear
Bearing
Bearing
No. 2 One-Way Clutch with
Rear Planetary Gear Rear Planetary
♦ O-Ring
Ring Gear
Plate Flange
Second Brake Drum
Race
Snap Ring
Thrust Washer Transaxle Rear Cover
Disc
Snap Ring
Piston Return Spring
♦ O-Ring
Snap Ring Snap Ring
Snap Ring
Disc
Snap Ring
Intermediate Shaft
Flange
Plate First and Reverse
Flange Brake Piston
COMPONENTS (Cont’d)
Underdrive Clutch
Counter Shaft Assembly Bearing
Roller Bearing
Underdrive Brake Piston
Disc
Flange
♦ Lock Nut
157 (1,600, 116)
Needle Bearing
♦ O-Ring
Plate
Snap Ring
♦ Spacer
COMPONENT PARTS
(See page AX-48 to AX-88 )
General Notes
The instructions here are organized so that you work on only one component group at a time.
This will help avoid confusion from similar-locking parts of different subassemblies being on your work-
bench at the same time.
The component groups are inspected and repaired from the converter housing side.
As much as possible, complete the inspection, repair and assembly before proceeding to the next com-
ponent group. If a component group can not be assembled because parts are being ordered, be sure to
keep all parts of that group in a separate container while proceeding with disassembly, inspection, repair
and assembly for other component groups.
PARTS ARRANGEMENT:
1. After cleaning, the parts should be arranged in proper order to allow efficient inspection,
repairs, and reassembly.
2. When disassembling a valve body, be sure to keep each valve together with the corre-
sponding spring.
3. New brakes and clutches that are to be used for replacement must be soaked in transmis-
sion fluid for at least fifteen minutes before assembly.
GENERAL ASSEMBLY:
1. All oil seal rings, clutch discs, clutch plates, rotating parts, and sliding surfaces should be
coated with transmission fluid prior to reassembly.
2. All gaskets and rubber O-rings should be replaced.
3. Make sure that the ends of a snap ring are not aligned with one of the cutouts and are
installed in the groove correctly.
4. If a worn bushing is to be replaced, the subassembly containing that bushing must be re-
placed.
5. Check thrust bearings and races for wear or damage. Replace if necessary.
6. Use petroleum jelly to keep parts in place.
AKPPHELP.RU Руководство по ремонту АКПП
AX-176
AUTOMATIC TRANSAXLE (A241H) - Component Parts (Valve Body)
Valve Body
COMPONENTS
Oil Tube
Clamp
♦ No. 1 Gasket
Plate
Plate ♦ Gasket
No. 2 Pressure
Regulator Valve
♦ No. 2 Gasket Body
♦ Gasket
Plate
♦ O-Ring
O/D Solenoid
AT3406
AT8372
AKPPHELP.RU Руководство по ремонту АКПП
AX-177
AUTOMATIC TRANSAXLE (A241H) - Component Parts (Valve Body)
AT8355
AT8356
AT8357
AT8358
AT8359
AKPPHELP.RU Руководство по ремонту АКПП
AX-178
AUTOMATIC TRANSAXLE (A241H) - Component Parts (Valve Body)
(b) Remove the five bolts from the lower valve body.
AT7982
(c) Hold the plate to the lower valve body and lift off
the lower valve body.
HINT: Be careful that the valves, springs and strainer do
not fall out.
AT8360
AKPPHELP.RU Руководство по ремонту АКПП
AX-179
AUTOMATIC TRANSAXLE (A241H) - Component Parts (Valve Body)
Primary Regulator
Plunger Sleeve No. 2 Pressure
Regulator Valve
Primary Regulator
Plunger No. 2 Pressure
Washer Regulator Valve Plunger Plug
Pin
Primary Regulator
Valve
Plug Spring
Darn Shift
Pin
Key Plug Check Ball
Throttle Valve Pin
Washer
Cam
Accumulator Con-
trol Valve
Plug
Plug
Key
AT3379
Q00982
AKPPHELP.RU Руководство по ремонту АКПП
AX-180
AUTOMATIC TRANSAXLE (A241H) - Component Parts (Valve Body)
Coil Outer
Free length Diameter Number of
Spring mm (in.) Coils Color
mm (in.)
Primary Regulator Valve Spring 66.7 (2.626) 18.6 (0.732) 12.5 Purple
Lock-Up Relay Valve Spring 18.8 (0.740) 5.1 (0.201) 14.5 None
2nd Coast Modulator Valve Spring 32.6 (1.283) 8.3 (0.327) 12.5 Blue
Down Shift Plug Spring 30.0 (1.181) 8.7 (0.343) 12.5 Blue
Throttle Valve Spring 29.2 (1.150) 9.2 (0.3622) 9.5 Light Green
Throttle Modulator Valve Spring 29.9 (1.177) 9.0 (0.354) 15.5 Green
Accumulator Control Valve Spring 38.2 (1.504) 10.0 (0.394) 11.5 Yellow
No. 2 Pressure Regulator Valve Spring 29.4 (1.157) 7.5 (0.295) 14.0 Red
HINT: During re-assembly please refer to the spring specifications above to help discriminate be-
tween the different springs.
Check Bail
Check Ball
Vibrating
Stopper
Key
Key
Pin Pin
Pin
Key
Pin
Pin
AT3382 AT3384
AKPPHELP.RU Руководство по ремонту АКПП
AX-181
AUTOMATIC TRANSAXLE (A241H) - Component Parts (Valve Body)
Strainer
Secondary Regulator
Valve
Plug
Key Low
Modulator
Low Coast Valve
3 - 4 Coast Shift Valve
Shift Valve
Key
3rd Coast Shift Valve
Plug
Plug Plug
Intermediate
Shift Valve
Key
3 - 4 Shift Valve
Lock-Up Signal
Valve
Plug
2 - 3 Shift Valve
Key
Key
Detent Regulator Valve
Plug Plug
Key
AT3381
AT3380
AKPPHELP.RU Руководство по ремонту АКПП
AX-182
AUTOMATIC TRANSAXLE (A241H) - Component Parts (Valve Body)
Coil Outer
Free Length Diameter Number of
Spring mm (in.) Color
mm (in.) Coils
Secondary Regulator Valve Spring 27.4 (1.079) 11.0 (0.433) 11.5 Blue
Low Modulator Valve Spring 29.2 (1.150) 8.3 (0.327) 12.5 None
Cooler By-pass Valve Spring 18.3 (0.720) 12.0 (0.472) 6.5 Yellow
Pressure Relief Valve Spring 11.2 (0.441) 6.4 (0.252) 7.5 None
Lock-up Signal Valve Spring 41.4 (1.630) 8.2 (0.323) 14.5 White
Detent Regulator Valve Spring 32.0 (1.260) 8.3 (0.327) 15.5 Brown
HINT: During re-assembly please refer to the spring specifications above to help discriminate be-
tween the different springs.
Key
Key
Key
Key
Key
Key Key
Key
Key
Key
Strainer
AT3386 AT3388
AKPPHELP.RU Руководство по ремонту АКПП
AX-183
AUTOMATIC TRANSAXLE (A241H) - Component Parts (Valve Body)
AT3383 AT3385
AT3389 AT3387
AKPPHELP.RU Руководство по ремонту АКПП
AX-184
AUTOMATIC TRANSAXLE (A241H) - Component Parts (Valve Body)
AT3409
(b) Make sure that the keys, pins, check balls and
vibrating stopper on the lower side of the upper
valve body and No. 2 pressure regulator valve
body are installed correctly. (See page AX-180 )
AT3407
AT3497
AT3496 AT3495
AT7983
AKPPHELP.RU Руководство по ремонту АКПП
AX-185
AUTOMATIC TRANSAXLE (A241H) - Component Parts (Valve Body)
AT8361
AT8362
AT3408
AT8368
Plate
Gasket
AT8369
AKPPHELP.RU Руководство по ремонту АКПП
AX-186
AUTOMATIC TRANSAXLE (A241H) - Component Parts (Valve Body)
AT8363
AT7993
AT8364
AT3405
AT8365
AKPPHELP.RU Руководство по ремонту АКПП
AX-187
AUTOMATIC TRANSAXLE (A241H) - Component Parts (Valve Body)
AT8366
AT8367
AT8371
AKPPHELP.RU Руководство по ремонту АКПП
AX-188
AUTOMATIC TRANSAXLE (A241H) - Component Parts (Valve Body)
Differential
COMPONENTS
Flange
Hole Snap
Ring
Shaft Snap Ring
Clutch Disk
Piston Return
29 (300, 22) Spring
♦ O-Ring
♦ O-Ring ♦ O-Ring
Gear Mounting
Case
Plate
Shaft Snap Ring
No. 1 Piton 124 (1,260, 91)
Piston Reaction Sleeve
No. 2 Piston Differential Side
Differential Pinion Thrust Washer No. 2
Thrust Washer Front Differential
Left Case
♦ Oil Seal Ring
Differential Pinion Pin
Differential Side
Thrust Washer No. 1
♦ Oil Seal
Plate Washer
♦ Left Side Bearing
N-m (kgf-cm, ft-lbf) : Specified torque
AT3365
♦ Non-reusable part
AKPPHELP.RU Руководство по ремонту АКПП
AX-189
AUTOMATIC TRANSAXLE (A241H) - Component Parts (Valve Body)
DISASSEMBLY OF DIFFERENTIAL
ASSEMBLY
1. CHECK DIFFERENTIAL END PLAY
Using a dial indicator, measure the differential end play.
End play: 0.18 - 0.82 mm (0.0071 - 0.0323 in.)
AT8270
AT8261
AT8262
AT8263
AT8264
AKPPHELP.RU Руководство по ремонту АКПП
AX-190
AUTOMATIC TRANSAXLE (A241H) - Component Parts (Valve Body)
AT8265
AT8276
AT8277
AT8377
AT8278
AKPPHELP.RU Руководство по ремонту АКПП
AX-191
AUTOMATIC TRANSAXLE (A241H) - Component Parts (Valve Body)
AT8279
AT8280
AT8271
SST
AT7754
AT8272
AKPPHELP.RU Руководство по ремонту АКПП
AX-192
AUTOMATIC TRANSAXLE (A241H) - Component Parts (Valve Body)
AT8273
AT8274
AT8275
AT7749
AT8297
AKPPHELP.RU Руководство по ремонту АКПП
AX-193
AUTOMATIC TRANSAXLE (A241H) - Component Parts (Valve Body)
AT7750
AT7751
AT7752
AT8287
AT8286
AKPPHELP.RU Руководство по ремонту АКПП
AX-194
AUTOMATIC TRANSAXLE (A241H) - Component Parts (Valve Body)
AT8289
AT8290
AT8281
Printed Number
INSPECTION OF DIFFERENTIAL LOCK
CLUTCH
INSPECT DISCS, PLATES AND FLANGE
Check that the sliding surface of disc, plate and flange
worn or burnt. If necessary, replace them.
HINT:
If the lining of the disc is exfoliated or discol-
ored, or even a part of the printed number are
defaced, replace all discs.
AT8288
Before assembling new discs, soak them in
ATF for at least fifteen minutes.
AKPPHELP.RU Руководство по ремонту АКПП
AX-195
AUTOMATIC TRANSAXLE (A241H) - Component Parts (Valve Body)
AT8471
AT7753
SST
AT7754
AT3498
Flange
(b) Install the flange with a facing the flat end down-
ward.
AT8282
AKPPHELP.RU Руководство по ремонту АКПП
AX-196
AUTOMATIC TRANSAXLE (A241H) - Component Parts (Valve Body)
AT7755
AT8279
AT3499
AT8283
AKPPHELP.RU Руководство по ремонту АКПП
AX-197
AUTOMATIC TRANSAXLE (A241H) - Component Parts (Valve Body)
AT8375
AT8285
AT8296
AKPPHELP.RU Руководство по ремонту АКПП
AX-198
AUTOMATIC TRANSAXLE (A241H) - Component Parts (Valve Body)
(d) Then quickly install the ring gear on the left case.
HINT: Align the matchmarks on the left case and ring
gear.
(e) Torque the ten bolts.
Torque: 124 N-m (1,260 kgf-cm, 91 ft-lbf)
AT8263
Matchmarks
AT7757
AT7758
AT8298
AKPPHELP.RU Руководство по ремонту АКПП
AX-199
AUTOMATIC TRANSAXLE (A241H) - Component Parts (Valve Body)
AT8299
AT8291
AKPPHELP.RU Руководство по ремонту АКПП
AX-200
AUTOMATIC TRANSAXLE (A241H) - Component Parts (Valve Body)
AT8292
SST
AT8293
AKPPHELP.RU Руководство по ремонту АКПП
AX-19
AUTOMATIC TRANSAXLE (A240L, A241E, A243L) - Removal of Component Parts
REMOVAL OF COMPONENT
PARTS (A241E, A243L)
COMPONENTS
Tube Clamp
Oil Pan
Oil Tube Bracket
10 (100, 7)
4.9 (50, 43 in.-lbf)
N-m (kgf-cm, ft-lbf) Specified torque ♦ Gasket
AT5722
♦ Non-reusable part Drain Plug
AKPPHELP.RU Руководство по ремонту АКПП
AX-20
AUTOMATIC TRANSAXLE (A240L, A241E, A243L) - Removal of Component Parts
COMPONENTS (Cont’d)
Second Coast
Brake Band
Forward Clutch
Pin
Bearing
Race Race
Bearing
One-W ay Clutch
Rear Planetary
One-W ay Ring Gear
Race
Clutch No. 2 Rear Planetary
Race Snap Ring Gear
Flange
Disc
Piston Return
Bearing
Spring
Snap Ring
Transaxle
Thrust Washer Rear Cover
Disc
Snap Ring Intermediate Shaft
Second Brake
Drum Seal 25 (250, 18)
Second Brake Apply Gasket
Second Coast
Plate Brake Band Guide
Flange
COMPONENTS (Cont’d)
29 (300, 22)
Clamp
Oil Tube Apply Cover
♦ Oil Tube Apply Cover Except A241E
Gasket
29 (300, 22) One-W ay Clutch No. 3
Pawl Shaft
Thrust Needle
♦ Lock Nut
Bearing
Pawl Shaft Clamp 157 (1,600, 116)
Parking Lock Paw
Plate
Transaxle Case
Apply Gasket
Except A241E
Differential Assembly
Cam Guide Bracket
Spring
130 (130, 9) Plate
Gasket
Spring Guide
Oil Gallery Cover
Stopper Plate
Parking Lock Sleeve
Screw
Bolt
Precoated part
AKPPHELP.RU Руководство по ремонту АКПП
AX-22
AUTOMATIC TRANSAXLE (A240L, A241E, A243L) - Removal of Component Parts
AT5637
AT5638
AT5639
(d) Remove the two bolts and pull out the neutral
start switch.
AT5640
AT5641
AKPPHELP.RU Руководство по ремонту АКПП
AX-23
AUTOMATIC TRANSAXLE (A240L, A241E, A243L) - Removal of Component Parts
AT5652
7. (A240L, A2431L)
REMOVE GOVERNOR BODY
(a) Remove the two bolts and cover brackets.
AT2848
AT2849
O-Ring
AT2850
Thrust
Washer
AT2851
AKPPHELP.RU Руководство по ремонту АКПП
AX-24
AUTOMATIC TRANSAXLE (A240L, A241E, A243L) - Removal of Component Parts
AT2852
AT5683
8. (A241E)
REMOVE SPEED SENSOR AND SENSOR ROTOR
(a) Remove the retaining plate and pull out the speed
sensor.
(b) Remove the O-ring from speed sensor.
AT5901
AT7926
AT7930
AKPPHELP.RU Руководство по ремонту АКПП
AX-25
AUTOMATIC TRANSAXLE (A240L, A241E, A243L) - Removal of Component Parts
AT5684
AT7932
AT2852
AT5645
AT2854
AT2855
AT2856
AT5685
AKPPHELP.RU Руководство по ремонту АКПП
AX-27
AUTOMATIC TRANSAXLE (A240L, A241E, A243L) - Removal of Component Parts
AT3135
A241E
AT2584
AT0108
AT5616
AKPPHELP.RU Руководство по ремонту АКПП
AX-28
AUTOMATIC TRANSAXLE (A240L, A241E, A243L) - Removal of Component Parts
AT0507
Solenoid
Wire
AT5692
AT1290
AT2859
AT5642
AKPPHELP.RU Руководство по ремонту АКПП
AX-29
AUTOMATIC TRANSAXLE (A240L, A241E, A243L) - Removal of Component Parts
AT2861
AT3111
AT2863
AT3141
AT2865
AKPPHELP.RU Руководство по ремонту АКПП
AX-30
AUTOMATIC TRANSAXLE (A240L, A241E, A243L) - Removal of Component Parts
AT2866
AT2867
AT2868
AT2869
SST
25. REMOVE OIL PUMP
(a) Remove the six bolts holding the oil pump to the
transmission case.
(b)Using SST, pull the oil pump free from the trans-
mission case.
SST 09350-32014 (09351-32061)
AT2871
AKPPHELP.RU Руководство по ремонту АКПП
AX-31
AUTOMATIC TRANSAXLE (A240L, A241E, A243L) - Removal of Component Parts
AT2872
AT0352
AT3035
AT0651
AT0652
AKPPHELP.RU Руководство по ремонту АКПП
AX-32
AUTOMATIC TRANSAXLE (A240L, A241E, A243L) - Removal of Component Parts
AT5618
AT2874
AT5595
AT0123 AT0124
AT5644
AKPPHELP.RU Руководство по ремонту АКПП
AX-33
AUTOMATIC TRANSAXLE (A240L, A241E, A243L) - Removal of Component Parts
AT5596
AT2878
AT5648
AT7891
AT0519
AKPPHELP.RU Руководство по ремонту АКПП
AX-34
AUTOMATIC TRANSAXLE (A240L, A241E, A243L) - Removal of Component Parts
AT2879
AT2880
AT2881
AT2882
AT2883
AKPPHELP.RU Руководство по ремонту АКПП
AX-35
AUTOMATIC TRANSAXLE (A240L, A241E, A243L) - Removal of Component Parts
AT2884
AT0139
AT2885
AT0324
AT7892
AKPPHELP.RU Руководство по ремонту АКПП
AX-36
AUTOMATIC TRANSAXLE (A240L, A241E, A243L) - Removal of Component Parts
AT2886
AT2887
AT5653
AT0521
AT0522
AKPPHELP.RU Руководство по ремонту АКПП
AX-37
AUTOMATIC TRANSAXLE (A240L, A241E, A243L) - Removal of Component Parts
AT2892
AT0523
AT0525
AT0526
AKPPHELP.RU Руководство по ремонту АКПП
AX-38
AUTOMATIC TRANSAXLE (A240L, A241E, A243L) - Removal of Component Parts
AT0527
AT2893
(A241E)
Remove the two gaskets.
AT5602
AT2894 AT2895
AT0529
AKPPHELP.RU Руководство по ремонту АКПП
AX-39
AUTOMATIC TRANSAXLE (A240L, A241E, A243L) - Removal of Component Parts
SST
AT0530 AT0531
SST
AT0532
AT0533
AT2896
AT0535
AKPPHELP.RU Руководство по ремонту АКПП
AX-40
AUTOMATIC TRANSAXLE (A240L, A241E, A243L) - Removal of Component Parts
AT8072
AT2897
AT7889
AT2898
AKPPHELP.RU Руководство по ремонту АКПП
AX-41
AUTOMATIC TRANSAXLE (A240L, A241E, A243L) - Removal of Component Parts
AT2899
AT2900
AT2901
AT2902
AT2903
AKPPHELP.RU Руководство по ремонту АКПП
AX-42
AUTOMATIC TRANSAXLE (A240L, A241E, A243L) - Removal of Component Parts
Spring Seat
AT0376
AT2888
SST
AT2889
AT5656
AT2891
AKPPHELP.RU Руководство по ремонту АКПП
AX-43
AUTOMATIC TRANSAXLE (A240L, A241E, A243L) - Removal of Component Parts
AT0541
AT0542
AT0543
AT0544
AT2904
AKPPHELP.RU Руководство по ремонту АКПП
AX-44
AUTOMATIC TRANSAXLE (A240L, A241E, A243L) - Removal of Component Parts
AT2905
AT2906
AT0547
(b) Slide out the manual valve shaft and remove the
manual valve lever and washer.
AT0548
AT2907
AKPPHELP.RU Руководство по ремонту АКПП
AX-45
AUTOMATIC TRANSAXLE (A240L, A241E, A243L) - Removal of Component Parts
AT2908
Q00981
AT2910
SST
AT0555
AT2911
AKPPHELP.RU Руководство по ремонту АКПП
AX-46
AUTOMATIC TRANSAXLE (A240L, A241E, A243L) - Removal of Component Parts
AT2912
AT2913
AT2915
AT2916
AKPPHELP.RU Руководство по ремонту АКПП
AX-201
AUTOMATIC TRANSAXLE (A241H) - Installation of Component Parts
INSTALLATION OF COMPONENT
PARTS (A241H)
Disassembly, inspection and assembly of each com-
ponent group have been indicated in the preceding
chapter.
Before assembly, make sure again that all compo-
nent groups are assembled correctly. If something
wrong is found in a certain component group during
assembly, inspect and repair this group immediately.
Recommended:
ATF Type T (08886 - 00405) or equivalent
GEAR OIL SUPER or equivalent
AT4331
AT2955
AKPPHELP.RU Руководство по ремонту АКПП
AX-203
AUTOMATIC TRANSAXLE (A241H) - Installation of Component Parts
mm (in.)
A B C D E F G H
AT3065
AT2915
AT3343
Torx Screw
AKPPHELP.RU Руководство по ремонту АКПП
AX-204
AUTOMATIC TRANSAXLE (A241H) - Installation of Component Parts
AT3346
Torx
Wrench
AT3347
AT8073
AT0593
AT2910
AKPPHELP.RU Руководство по ремонту АКПП
AX-205
AUTOMATIC TRANSAXLE (A241H) - Installation of Component Parts
AT5696
AT5643
AT0548
AT0547
9. INSTALL PIN
(a) Using a punch and hammer, drive in the pin.
(b) Position the spacer and stake it.
AT2959
AKPPHELP.RU Руководство по ремонту АКПП
AX-206
AUTOMATIC TRANSAXLE (A241H) - Installation of Component Parts
AT0545
AT0544
AT8097
(b) Align the pawl shaft groove and shaft clamp cut
position.
(c) Install the shaft clamp.
AT8095
AT8052
AKPPHELP.RU Руководство по ремонту АКПП
AX-207
AUTOMATIC TRANSAXLE (A241H) - Installation of Component Parts
AT2960
(c) Place the piston into the case with the cup side
up, being careful not to damage O-rings.
AT2961
AT2901
AT2900
AT2899
AKPPHELP.RU Руководство по ремонту АКПП
AX-208
AUTOMATIC TRANSAXLE (A241H) - Installation of Component Parts
AT7889
AT2898
AT1292
AT1289
AT0597
AKPPHELP.RU Руководство по ремонту АКПП
AX-209
AUTOMATIC TRANSAXLE (A241H) - Installation of Component Parts
17.3 - 18.2 mm
AT7987
AT8072
AT1293
AT1294
AKPPHELP.RU Руководство по ремонту АКПП
AX-210
AUTOMATIC TRANSAXLE (A241H) - Installation of Component Parts
AT2896
AT7988
AT0533
AT8084
AT0603
AKPPHELP.RU Руководство по ремонту АКПП
AX-21 1
AUTOMATIC TRANSAXLE (A241H) - Installation of Component Parts
AT0076
AT0604
AT2962
(c) Place the piston into the bore of the case, facing
the spring seats upward.
(d) Using SST, press into the piston.
SST 09350-32014 (09351-32040)
HINT: Be careful not to damage the O-rings.
(e) Remove SST.
AT2963 SST
AT2888 SST
AT0523
AT2892
AT7911
AT8094
AKPPHELP.RU Руководство по ремонту АКПП
AX-213
AUTOMATIC TRANSAXLE (A241H) - Installation of Component Parts
AT2893
AT0527
AT0526
AT0606
AT0607
AKPPHELP.RU Руководство по ремонту АКПП
AX-214
AUTOMATIC TRANSAXLE (A241H) - Installation of Component Parts
AT3501
(c) Install the outer flange, the flat end facing down-
ward.
AT3500
AT0610
AT7892
AT0612
(c) Install the rear planetary ring gear into the case.
AT0613
AT0323
AT0614
AT2965
AKPPHELP.RU Руководство по ремонту АКПП
AX-216
AUTOMATIC TRANSAXLE (A241H) - Installation of Component Parts
AT2966
Free
Lock
AT0616
AT0617
AT0519
AT0618
AKPPHELP.RU Руководство по ремонту АКПП
AX-217
AUTOMATIC TRANSAXLE (A241H) - Installation of Component Parts
AT2967
AT0620
AT0621
AT0622
AT2592
AKPPHELP.RU Руководство по ремонту АКПП
AX-218
AUTOMATIC TRANSAXLE (A241H) - Installation of Component Parts
AT7891
AT0626
(b) Align the spline of the hub with the flukes of the
discs and install the hub to the second brake
discs.
AT0627
AT5720
AT0828
AKPPHELP.RU Руководство по ремонту АКПП
AX-219
AUTOMATIC TRANSAXLE (A241H) - Installation of Component Parts
AT2759
AT0631
AT2868
HINT: If the planetary ring gear and the other parts are
installed correctly into the case, the end of the bushing
with the ring gear flange will be flush with a shoulder of
the intermediate shaft or under.
AT2023
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AX-220
AUTOMATIC TRANSAXLE (A241H) - Installation of Component Parts
(c) Coat the races and bearing with petroleum jelly and
install them onto the tip of ring gear flange as shown.
Bearing and races mm (in.)
Outer diameter Inner diameter
AT2969
Pin
AT0635
AT2970
AT0349
AT0350
AKPPHELP.RU Руководство по ремонту АКПП
AX-221
AUTOMATIC TRANSAXLE (A241H) - Installation of Component Parts
(d) Mesh the hub with the flukes of the direct clutch
while turning the clutch drum or forward clutch.
HINT: If the flukes of the discs are meshed with the hub
correctly, the end of the bushing with the direct clutch
drum will be flush with the surface of the forward clutch.
(e) Place the direct clutch and forward clutch into the
case.
(f) While rotating the forward clutch to mesh the front
planetary ring gear and discs, install them.
AT2971
AT2595
AT3348
AT8076
AT8048
AT2766
AT2972
(c) Place the oil pump through the input shaft, and
align the bolt holes of the pump body with the
transmission case.
(d) Hold the input shaft, and lightly press the oil pump
body to slide the oil seal rings on the stator shaft
through the direct clutch drum.
NOTICE: Do not push on the oil pump strongly, or the
oil seal ring will stick to the direct clutch drum.
(e) Install and tighten the six bolts.
AT0637
Torque: 25 N-m (250 kgf-cm, 18 ft-lbf)
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AX-223
AUTOMATIC TRANSAXLE (A241H) - Installation of Component Parts
AT3345
AT2870
(b) Install the spring, piston and cover into the bore.
AT2869
AT2867
AKPPHELP.RU Руководство по ремонту АКПП
AX-224
AUTOMATIC TRANSAXLE (A241H) - Installation of Component Parts
AT2865
AT2866
AT3036
AT1290
AKPPHELP.RU Руководство по ремонту АКПП
AX-225
AUTOMATIC TRANSAXLE (A241H) - Installation of Component Parts
AT0643
AT3114
AT0108
AT0645
Clamp
AT3433
AKPPHELP.RU Руководство по ремонту АКПП
AX-226
AUTOMATIC TRANSAXLE (A241H) - Installation of Component Parts
AT3135
AT3430
AT3431
AT2854
AKPPHELP.RU Руководство по ремонту АКПП
AX-227
AUTOMATIC TRANSAXLE (A241H) - Installation of Component Parts
AT5645
AT3440
AT7992
AT8499
AT8057
AKPPHELP.RU Руководство по ремонту АКПП
AX-228
AUTOMATIC TRANSAXLE (A241H) - Installation of Component Parts
AT8051
AT8071
O-Ring
AT2850
AT8053
AT0502
AKPPHELP.RU Руководство по ремонту АКПП
AX-229
AUTOMATIC TRANSAXLE (A241H) - Installation of Component Parts
AT0501
AT8040
AT8006
Groove
AT7762
AT8041
AKPPHELP.RU Руководство по ремонту АКПП
AX-230
AUTOMATIC TRANSAXLE (A241H) - Installation of Component Parts
(j) Install the manual shift lever with the washer, and
tighten the nut.
Torque: 13 N-m (130 kgf-cm, 9 ft-lbf)
AT8496
AT8050
254 mm
Protrusion Length (Reference): 254 mm (10.0 in.)
AT7763
Apply
Gasket
AT3355
AT8074
Lock
Free
AT3447
AKPPHELP.RU Руководство по ремонту АКПП
AX-47
AUTOMATIC TRANSAXLE - Component Parts (General Notes)
COMPONENT PARTS
General Notes
The instructions here are organized so that you work on only one component group at a time.
This will help avoid confusion from similar-locking parts of different subassemblies being on your work-
bench at the same time.
The component groups are inspected and repaired from the converter housing side.
As much as possible, complete the inspection, repair and assembly before proceeding to the next com-
ponent group. If a component group can not be assembled because parts are being ordered, be sure to
keep all parts of that group in a separate container while proceeding with disassembly, inspection, repair
and assembly for other component groups.
PARTS ARRANGEMENT:
1. After cleaning, the parts should be arranged in proper order to allow efficient inspection,
repairs, and reassembly.
2. When disassembling a valve body, be sure to keep each value together with the corre-
sponding spring.
3. New brakes and clutches that are to be used for replacement must be soaked in transmis-
sion fluid for at least fifteen minutes before assembly.
GENERAL ASSEMBLY:
1. All oil seal rings, clutch discs, clutch plates, rotating parts, and sliding surfaces should be
coated with transmission fluid prior to reassembly.
2. All gaskets and rubber O-rings should be replaced.
3. Make sure that the ends of a snap ring are not aligned with one of the cutouts and are
installed in the groove correctly.
4. If a worn bushing is to be replaced, the subassembly containing that bushing must be re-
placed.
5. Check thrust bearings and races for wear or damage. Replace if necessary.
6. Use petroleum jelly to keep parts in place.
AKPPHELP.RU Руководство по ремонту АКПП
AX-48
AUTOMATIC TRANSAXLE - Component Parts (Second Coast Brake)
Outer Spring
Piston Rod
Pin
Plate Washer
Second Coast Inner Spring
Oil Seal Ring
Brake Band
Piston
E-Ring ♦ O-Ring
Cover
Snap Ring
♦ Non-reusable part
AT5657
AT7702
AT7703
AKPPHELP.RU Руководство по ремонту АКПП
AX-49
AUTOMATIC TRANSAXLE - Component Parts (Second Coast Brake)
AT7704
AT8098
AT7704
AT7706
AKPPHELP.RU Руководство по ремонту АКПП
AX-50
AUTOMATIC TRANSAXLE - Component Parts (Second Coast Brake)
AT7707
AKPPHELP.RU Руководство по ремонту АКПП
AX-51
AUTOMATIC TRANSAXLE - Component Parts (Oil Pump)
Oil Pump
Stator Shaft
Pump Body
Driven Gear
10 (100, 7)
Race
Thrust Washer
Drive Gear
♦ O-Ring
♦ Oil Seal
AT1050
AT0151
AKPPHELP.RU Руководство по ремонту АКПП
AX-52
AUTOMATIC TRANSAXLE - Component Parts (Oil Pump)
AT3611
AT2732
AT0154
AT0155
AKPPHELP.RU Руководство по ремонту АКПП
AX-53
AUTOMATIC TRANSAXLE - Component Parts (Oil Pump)
If the thickest gear can not make the side clearance with-
in standard specification, replace the oil pump body sub-
assembly.
4. CHECK OIL PUMP BODY BUSHING
Using a dial indicator, measure the inside diameter of
the oil pump body bushing.
Maximum inside diameter: 38.18 mm (1.5051 in.)
If the inside diameter is greater than the maximum, re-
place the oil pump body subassembly.
AT7708
AT8090
AT0156
AT0157
AKPPHELP.RU Руководство по ремонту АКПП
AX-54
AUTOMATIC TRANSAXLE - Component Parts (Oil Pump)
AT3611
AT0159
AT0160
AT0161
AKPPHELP.RU Руководство по ремонту АКПП
AX-55
AUTOMATIC TRANSAXLE - Component Parts (Direct Clutch)
Direct Clutch
Flange
Plate
A241E
Flange
Flange
Plate
A240L
Snap Ring
Disc
AT6474
♦ Non-reusable part
AT7710
AKPPHELP.RU Руководство по ремонту АКПП
AX-56
AUTOMATIC TRANSAXLE - Component Parts (Direct Clutch)
AT0163
AT2733
AT2734
AT0165
AT2735
AKPPHELP.RU Руководство по ремонту АКПП
AX-57
AUTOMATIC TRANSAXLE - Component Parts (Direct Clutch)
AT0166 AT0167
AT3231
AT0168
A241E 3. (A243L)
INSTALL CUSHION PLATE ROUNDED END DOWN
Flange
Disc Plate
Cushion
Plate
AT5832
AT7710
AKPPHELP.RU Руководство по ремонту АКПП
AX-64
AUTOMATIC TRANSAXLE - Component Parts (Front Planetary Gear)
Thrust Washer
Sun Gear
Planetary Gear
Ring Gear
Ring Gear
Flange No. 1 One-Way Clutch
and B2 Hub
Bearing Race Snap Ring
Snap Ring
AT2697
AT0185
AT0186
AKPPHELP.RU Руководство по ремонту АКПП
AX-65
AUTOMATIC TRANSAXLE - Component Parts (Front Planetary Gear)
AT0187
AT2740
AT8081
AT0187
AKPPHELP.RU Руководство по ремонту АКПП
AX-66
AUTOMATIC TRANSAXLE - Component Parts (Front Planetary Gear)
AT0185
AT7714
AT7715
AKPPHELP.RU Руководство по ремонту АКПП
AX-67
AUTOMATIC TRANSAXLE - Component Parts (Second Brake)
Second Brake
Flange
Disc
Plate
♦ O-Ring
Piston
Snap Ring
AT2698
♦ Non-reusable part
AT7716
AT2742
AKPPHELP.RU Руководство по ремонту АКПП
AX-68
AUTOMATIC TRANSAXLE - Component Parts (Second Brake)
AT2743
(c) Press the piston into the drum, being careful not
to damage the O-rings.
AT2744
AKPPHELP.RU Руководство по ремонту АКПП
AX-69
AUTOMATIC TRANSAXLE - Component Parts (Rear Planetary Gear)
Snap Ring
Ring Gear
Rear Planetary
Gear
Outer Race
No. 2 One-Way
Clutch
Flange
Bearing and Races
Thrust Washers
Snap Ring
Retainers
Snap Ring
AT2699
AT0191
AT0323
AKPPHELP.RU Руководство по ремонту АКПП
AX-70
AUTOMATIC TRANSAXLE - Component Parts (Rear Planetary Gear)
AT0192
AT0193
AT0192
AT0649
Turn
AT0191
AKPPHELP.RU Руководство по ремонту АКПП
AX-71
AUTOMATIC TRANSAXLE - Component Parts (Rear Planetary Gear)
AT0323
AT7717
AT8055
AT7717
Flange
Plate
Flange
Piston
Snap Ring ♦ O-Ring
Piston Return
Spring
Snap Ring
Disc
Intermediate Shaft
Rear Bearing
Intermediate Shaft
Front Bearing
AT2919
AT0200
AT2920
AKPPHELP.RU Руководство по ремонту АКПП
AX-74
AUTOMATIC TRANSAXLE - Component Parts (Intermediate Shaft)
AT2921
(b) Check that the distance from the gear flange end
115.8 mm to the intermediate shaft end should be 115.8 mm
(4.559 in.) (4.559 in.).
AT1297
AT2922
AKPPHELP.RU Руководство по ремонту АКПП
AX-75
AUTOMATIC TRANSAXLE - Component Parts (Counter Shaft)
Counter Shaft
Outer Race
Inner Race
Bearing
Snap Ring
Bearing
Bearing
Planetary Sun Gear
Race
Snap Ring
Underdrive
Planetary Gear
AT2924
SST
2. MEASURE STARTING TORQUE OF COUNTER
SHAFT
(a) Using SST, temporarily tighten the lock nut.
SST 09350-32014 (09351-32170)
AT2925
AKPPHELP.RU Руководство по ремонту АКПП
AX-76
AUTOMATIC TRANSAXLE - Component Parts (Counter Shaft)
SST (b) Using soft jaws, hold the drive pinion in a vise.
(c) Using SST and spring tension gauge, measure the
starting torque of the counter shaft.
SST 09350-32014 (09351-32170)
Starting torque: with spring tension gauge
12 - 20 N
(1.2 - 2.0 kg, 2.6 - 4.4 lb)
with torque gauge
(hexagon nut side)
AT2926 New bearing
0.6 - 1.0 N-m
(6 - 10 kgf-cm, 5.2 - 8.7 in.-lbf)
SST Reused bearing
0.3 - 0.5 N-m
(3 - 5 kgf-cm, 2.6 - 4.3 in.-lbf)
If the torque is exceeded, replace the spacer.
(a) Using SST, remove the lock nut.
SST 09350-32014 (09351-32170)
AT2925
AT2927
AT0563
AT0564
AKPPHELP.RU Руководство по ремонту АКПП
AX-77
AUTOMATIC TRANSAXLE - Component Parts (Counter Shaft)
AT0565
AT2928
AT2929
AT2930
AT2931
AKPPHELP.RU Руководство по ремонту АКПП
AX-78
AUTOMATIC TRANSAXLE - Component Parts (Counter Shaft)
9. REMOVE BEARING
SST
Using SST and press, remove the bearing.
SST 09950-00020
AT0568
AT2932
AT0581
AT2934
SST
SST
AT7921
AT2929
AT0582
AKPPHELP.RU Руководство по ремонту АКПП
AX-80
AUTOMATIC TRANSAXLE - Component Parts (Counter Shaft)
SST
AT2935
SST
AT2936
SST
AT7922
SST
AT0588
SST
AT2937
AKPPHELP.RU Руководство по ремонту АКПП
AX-81
AUTOMATIC TRANSAXLE - Component Parts (Counter Shaft)
Fulcrum Length (d) Temporarily install the new lock nut, and using SST,
tighten the lock nut until the counter shaft starting
torque is in specification.
SST SST 09350-32014 (09361-32170)
Torque (Reference): 117 - 216 N-m
(A241E, A243L) (1,800 - 2,200 kgf-cm,
130 - 159 ft-lbf)
Torque (Reference): 157 - 193 N-m
(A240L, A241H) (1,610 - 1,970 kgf-cm,
AT0589
116 - 142 ft-lbf)
HINT: Use a torque wrench with a fulcrum length of 42 cm
(16.54 in.).
SST (e) Using soft jaws, , hold the drive pinion in a vise.
(f) Using SST and spring tension gauge, measure the
starting torque of the counter shaft.
SST 09350-32014 (09351-32170)
Starting torque: with tension gauge
12 - 20 N
(1.2 - 2.0 kg, 2.6 - 4.4 lb)
with torque gauge
AT0590
(hexagon nut side)
New bearing
0.6 - 1.0 N-m
(6 - 10 kgf-cm, 5.2 - 8.7 in.-bf)
Reused bearing
0.3 - 0.5 Nrrn
(3 - 5 kgf-cm, 2.6 - 4.3 in.-lbf)
If the starting torque is exceeded, replace the spacer and
retorque.
HINT: Before measuring the starting torque, sung down
the bearing by turning the counter shaft.
(g) Using a punch and hammer, stake the lock nut.
AT2938
SST
AT0588
AT2939
AKPPHELP.RU Руководство по ремонту АКПП
AX-82
AUTOMATIC TRANSAXLE - Component Parts (Counter Shaft)
AT0565
A240L Race 41.8 (1.646) 30.0 (1.181)
A241H Bearing 43.7 (1.720) 31.0 (1.220)
AT0585
AT2940
AT2927
AT2924
AKPPHELP.RU
AUTOMATIC TRANSAXLE
Руководство по ремонту АКПП
- Component Parts (Underdrive Clutch AX-83
and One-Way Clutch No. 3)
A241E
A240L
A241H
A243L
Oil Seal Ring
Plate
Disc
Flange One-W ay Clutch
Snap Ring
Piston
Spring Plate
Thrust
Washer
Snap Ring
♦ O-Ring
Anti-Rattle
Return Spring Clip
Underdrive Clutch Drum
AT5838
♦ Non-reusable part
Thrust Washer
DISASSEMBLY OF UNDERDRIVE CLUTCH
1. REMOVE ONE-WAY CLUTCH FROM CLUTCH
DRUM
Remove the one-way clutch and thrust washer from
the underdrive clutch drum.
AT2942
AT0572
AKPPHELP.RU
AUTOMATIC TRANSAXLE
Руководство по ремонту АКПП
- Component Parts (Underdrive Clutch
AX-84
and One-Way Clutch No. 3)
AT3112
AT2944
AT2945
AT2947
AKPPHELP.RU
AUTOMATIC TRANSAXLE
Руководство по ремонту АКПП
- Component Parts (Underdrive Clutch AX-85
and One-Way Clutch No. 3)
AT5837
AT0576 AT0577
AT2949
AT2950
Spring Seat
AT2945
AT2944
Stopper
Stopper
AT8000
AKPPHELP.RU
AUTOMATIC TRANSAXLE
Руководство по ремонту АКПП
- Component Parts (Underdrive Clutch AX-87
and One-Way Clutch No. 3)
AT3113
AT2952
AT2942
AT8001
AKPPHELP.RU
AUTOMATIC TRANSAXLE
Руководство по ремонту АКПП
- Component Parts (Underdrive Brake and B4
AX-88
Accumulator Piston)
Return Spring
Disc
Snap Ring
♦ O-Ring
Flange Plate
♦ Gasket
B4 Accumulator Piston
Spring
♦ O-Ring
Oil Gallery Cover
Bolt
10 (100, 7)
Valve Body
COMPONENTS
♦ No. 1 Gasket
Plate
♦ No. 2 Gasket
♦ Gasket
♦ Gasket
Plate
Lower Valve Plate
♦ O-Ring Body Cover ♦ Gasket
♦ O-Ring
♦ O-Ring
No. 3 Solenoid
No. 1 Solenoid Solenoid
6.5 (65, 56 in.-lbf) Lower Valve Body Cover
No. 2 Solenoid 6.5 (65, 56 in.-lbf)
N-m (kgf-cm, ft-lbf) Specified torque
AT8455 AT3140
Stainer
♦ Non-reusable part 10 (100, 7)
AT3138
A241E
AT5724
AT3046
A241E (A241E)
Remove the ten bolts and the lower valve body cover.
AT8033
AT3047
AKPPHELP.RU Руководство по ремонту АКПП
AUTOMATIC TRANSAXLE (A240L, A241E, A243L) - Component Parts (Valve Body) AX-91
A241E Gasket
Plate
Gasket
AT8032
AT3048
AT3058
AT3055
A241E Remove the nine bolts from the lower valve body.
(A241E)
AT2588
AKPPHELP.RU Руководство по ремонту АКПП
AX-92
AUTOMATIC TRANSAXLE (A240L, A241E, A243L) - Component Parts (Valve Body)
Adjusting Ring
The throttle pressure is changed
according to the number of adjust-
ing rings.
When assembling the valve body,
install the same number of adjust-
ing rings as were removed.
Check Ball
Plug
Vibrating Stopper
Check Ball
Strainer*1
Pin
Cam
Washer
Strainer*1
Pin
Plug
Pin
AT5712
N-m (kgf-cm, ft-lbf) : Specified torque*1A241E Only*2 A241E and A240L Only
AKPPHELP.RU Руководство по ремонту АКПП
AX-94
AUTOMATIC TRANSAXLE (A240L, A241E, A243L) - Component Parts (Valve Body)
Coil Outer
Free Length Diameter mm Number of
Spring mm (in.) Color
(in.) Coils
Primary Regulator Valve Spring 66.7 (2.626) 18.6 (0.732) 12.5 Purple
Lock-up Relay Valve Spring 18.8 (0.740) 5.1 (0.201) 14.5 None
Low Coast Modulator Valve Spring A241E 27.5 (1.083) 8.3 (0.327) 12.5 Yellow
White
(A240L)
Red
Down Shift Plug Spring 29.8 (1.173) 8.7 (0.343) 13.5
A241E
A243L
Throttle Valve Spring 29.2 (1.150) 9.2 (0.362) 9.5 Light Green
Throttle Modulator Valve Spring 29.9 (1.177) 9.0 (0.354) 15.5 Green
HINT: During reassembly please refer to the spring specifications above to help discriminate be-
tween the different springs.
SECTIONAL VIEW OF VALVE BODY
AT8488
AKPPHELP.RU Руководство по ремонту АКПП
AX-95
AUTOMATIC TRANSAXLE (A240L, A241E, A243L) - Component Parts (Valve Body)
Pin
Key
Key
Vibrating Stopper
Pin
Pin
Key Pin mm (in.)
2. CHECK BALL
A241E A240L
A243L
AT5678 AT5679
AKPPHELP.RU Руководство по ремонту АКПП
AX-96
AUTOMATIC TRANSAXLE (A240L, A241E, A243L) - Component Parts (Valve Body)
Key
Cooler By-Pass Valve Plug
Strainer
Key
Plug
2nd Coast Modulator Valve
Key
Key
Plug
1 - 2 Shift Valve
Plug
Key
3 - 4 Shift Valve
Plug
Key
AT8374
AKPPHELP.RU Руководство по ремонту АКПП
AX-97
AUTOMATIC TRANSAXLE (A240L, A241E, A243L) - Component Parts (Valve Body)
Cooler By-pass Valve Spring 18.3 (0.720) 12.0 (0.472) 6.5 Yellow
Pressure Relief Valve Spring 11.2 (0.441) 6.4 (0.252) 7.5 None
2nd Coast Modulator Valve Spring 29.6 (1.165) 8.3 (0.327) 12.5 Red
Lock-up Signal Valve Spring 30.0 (1.181) 8.2 (0.323) 11.5 Orange
Secondary Regulator Valve Spring 27.4 (1.079) 11.0 (0.433) 11.5 Blue
HINT: During reassembly please refer to the spring specifications above to help discriminate be-
tween the different springs:
Q04983
AKPPHELP.RU Руководство по ремонту АКПП
AX-98
AUTOMATIC TRANSAXLE (A240L, A241E, A243L) - Component Parts (Valve Body)
Key
Key Key
mm (in.)
AT5726 AT5727
AKPPHELP.RU Руководство по ремонту АКПП
AX-99
AUTOMATIC TRANSAXLE (A240L, A241E, A243L) - Component Parts (Valve Body)
Stainer
Plug
Key
Key
Low Coast
Shift Valve
Key
3rd Coast Shift Valve
Low Modulator Plug
Valve Intermediate Plug
Shift Valve
Key
3 - 4 Shift Valve
Plug
AT3051 Key
AT3052
AKPPHELP.RU Руководство по ремонту АКПП
AX-100
AUTOMATIC TRANSAXLE (A240L, A241E, A243L) - Component Parts (Valve Body)
Secondary Regulator Valve Spring 27.4 (1.079) 11.0 (0.433) 11.5 Blue
Low Modulator Valve Spring 29.2 (1.150) 8.3 (0.327) 12.5 None
Cooler By-pass Valve Spring 18.3 (0.720) 12.0 (0.472) 6.5 Yellow
Pressure Relief Valve Spring 11.2 (0.441) 6.4 (0.252) 7.5 None
3 - 4 Shift Valve Spring A240L, A243L 27.7 (1.091) 8.3 (0.327) 11.0 None
Detent Regulator Valve Spring 32.0 (1.260) 8.3 (0.327) 15.5 Brown
HINT: During reassembly please refer to the spring specifications above to help discriminate be-
tween the different springs.
Q00984
AKPPHELP.RU Руководство по ремонту АКПП
AX-101
AUTOMATIC TRANSAXLE (A240L, A241E, A243L) - Component Parts (Valve Body)
key
Strainer
key
key
key key key
AT3057 AT3053
mm (in.)
Key Height Width Thickness
FOREWORD
REPAIR PROCEDURES
Most repair operations begin with an overview illustration. It
identifies the components and shows how the parts fit together.
Example:
Drive Gear
Stator Shaft
Driven Gear
♦ Oil Seal
Example:
Task heading: what to do
REFERENCES
References have been kept to a minimum. However, when
they are required you are given the page to go to.
SPECIFICATIONS
Specifications are presented in bold type throughout the text in
the applicable step. You never have to leave the procedure to
look up your specs. All specifications are also found at the
back of AX section, specifications for quick reference.
CAUTIONS, NOTICES, HINTS:
CAUTIONS are presented in bold type, and indicate
there is a possibility of injury to you or other people.
NOTICES are also presented in bold type, and indicate
the possibility of damage to the components being re-
paired.
HINTS are separated from the text but do not appear in
bold. They provide additional information to help you effi-
ciently perform the repair.
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TR-40
TRANSFER (A241H) - Service Specifications
SERVICE SPECIFICATIONS
SERVICE DATA
Transfer driven pinion preload (at starting) 8.8 - 13.7 N 0.9 - 1.4 kg 2.0 - 3.1 lb
w/ Transfer (Add driven pinion preload)
New bearing 12.7 - 13.7 N 1.3 - 1.4 kg 2.7 - 3.1 lb
Reused bearing 4.9 - 8.8 N 0.5 - 0.9 kg 1.1 - 2.0 lb
Drive pinion bearing cage preload (at starting)
New bearing 17.7 - 28.4 N 1.8 - 2.9 kg 4.0 - 6.4 lb
Reused bearing 8.8 - 13.7 N 0.9 - 1.4 kg 2.0 - 3.1 lb
Backlash
Transfer ring gear 0.13 - 0.18 mm 0.0051 - 0.0071 in.
Oil seal depth
Transfer left case 3 mm 0.12 in.
Transfer right case Left side 0 mm 0 in
Right side 0 mm 0 in.
Extension housing 0.1 - 0.9 mm 0.004 - 0.035 in.
TORQUE SPECIFICATIONS
SERVICE SPECIFICATIONS
SERVICE DATA
Second coast Piston stroke 1.5 - 3.0 mm 0.059 - 0.118 in.
brake Piston rod length 72.9 mm 2.870 in.
71.4 mm 2.811 in.
Oil pump Body clearance STD 0.07 - 0.15 mm 0.0028 - 0.0059 in.
Maximum 0.3 mm 0.012 in.
Tip clearance STD 0.11 - 0.14 mm 0.0043 - 0.0055 in.
Maximum 0.3 mm 0.012 in.
Side clearance STD 0.02 - 0.05 mm 0.0008 - 0.0020 in.
Maximum 0.1 mm 0.004 in.
Pump body bushing inside diameter Maximum 38.18 mm 1.5031 in.
Stator shaft bushing inside diameter
Front side Maximum 21.57 mm 0.8492 in.
Rear side Maximum 27.07 mm 1.0657 in.
Direct clutch Piston stroke A241E 1.11 - 1.47 mm 0.0437 - 0.0579 in.
A243L 1.63 - 1.97 mm 0.0642 - 0.0776 in.
A240L, A241H 1.36 - 1.71 mm 0.0535 - 0.0673 in.
Drum bushing inside diameter 47.07 mm 1.8531 in.
Flange thickness A241E 2.6 mm 0.102 in.
A243L 3.0 mm 0.118 in.
A240L, A241H 2.6 mm 0.102 in.
2.8 mm 0.110 in.
3.0 mm 0.118 in.
3.0 mm 0.118 in.
3.37 mm 0.1327 in.
Forward Piston stroke 1.42 - 1.81 mm 0.0559 - 0.0713 in.
clutch Flange thickness 3.00 mm 0.1181 in.
3.37 mm 0.1327 in.
Front planetary Sun gear bushing inside diameter Standard 22.025 - 22.046 mm 0.8671 - 0.8680 in.
gear Maximum 22.096 mm 0.8699 in.
Ring gear flange bushing inside diameter
Standard 19.025 - 19.050 mm 0.7490 - 0.7500 in.
Planetary pinion gear thrust clearance
Maximum 0.5 mm 0.020 in.
Rear planetary Planetary pinion gear thrust clearance
gear Maximum 0.5 mm 0.020 in.
Counter shaft Starting torque with spring tension gauge 1.2 - 2.0 kg 2.6 - 4.4 lb
with torque gauge
(hexagon nut side) New bearing 0.6 - 1.0 N-m 6 - 10 kgf-cm 5.2 - 8.7 in.-lbf
Reused bearing 0.3 - 0.5 N-m 3 - 5 kgf-cm 2.6 - 4.3 in.-lbf
Planetary sun gear bushing inside diameter
Standard 29.800 - 29.825 mm 1.1732 - 1.1742 in.
Maximum 29.870 mm 1.1760 in.
Underdrive planetary pinion gear thrust clearance
Maximum 0.5 mm 0.020 in.
Height (measure the distance between the tip of the 33.3 - 35.5 mm 1.311 - 1.398 in.
counter shaft and bolt seat of the clutch support.)
End play 0.23 - 0.89 mm 0.0091 - 0.0350 in.
AKPPHELP.RU Руководство по ремонту АКПП
AX-233
AUTOMATIC TRANSAXLE - Service Specifications
Blue and
C2 71.5 (2.815)
Light blue
C3 61.47 (2.420) White
Differential (A241H)
(Cont’d) Center differential backlash 0.13 - 0.18 mm 0.0051 - 0.0071 in.
Center differential case thrust clearance
STD 0.18 - 0.63 mm 0.0071 - 0.0248 in.
Differential end play 0.18 - 0.82 mm 0.0071 - 0.0323 in.
(A241H) Mark
Center differential side gear thrust A 1.00 mm 0.0394 in.
washer B 1.05 mm 0.0413 in.
C 1.10 mm 0.0433 in.
D 1.15 mm 0.0453 in.
E 1.20 mm 0.0472 in.
F 1.25 mm 0.0492 in.
G 1.30 mm 0.0512 in.
H 1.35 mm 0.0531 in.
J 1.40 mm 0.0551 in.
TORQUE SPECIFICATIONS
Part tightened kg-cm ft-lb N-m
PREPARATION
SST (SPECIAL SERVICE TOOLS)
A241H
Crankshaft Rear
09223-15010 Oil Seal Replacer
A241H
09226-10010 Crankshaft Front & Rear
Bearing Replacer
A241H
Transfer Bearing
09316-12010 Replacer
A241H
Transfer Bearing
09316-20011 Replacer
A241H
(09316-00010) (Replacer Pipe)
A241H
(09316-00030) (Replacer ”B”)
A241H
(09316-00040) (Replacer ”C”)
A241H
(09316-00060) (Replacer ”E”)
A241H
Transfer Bearing
09318-12010 Adjusting Nut Wrench
A241H
Output Shaft Bearing
09326-20011 Lock Nut Wrench
Companion Flange
09330-00021 Holding Tool
TOYOTA Automatic
09350-32014 Transmission Tool
Set
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AX-12
AUTOMATIC TRANSAXLE - Preparation
Except A241H
(09351-32111) Side Bearing Race
Replacer
(09351-32130) (Handle)
Differential Side
09502-10012 Bearing Puller
AKPPHELP.RU Руководство по ремонту АКПП
AX-13
AUTOMATIC TRANSAXLE - Preparation
A241H
Differential Bearing
09502-12010 Replacer
Except A241H
09564-32011 Differential
Preload Adaptor
A241H
09608-30022 Front Hub Searing
Replacer Set
A241H
Drive Pinion Front
(09608-00050) Bearing Cup Replacer
A241H
(09608-05010) (Handle)
A241H
(09608-06020) (Handle)
A241H
Front Hub Outer
(09608-06120) Bearing Cup Replacer
A241H
Rear Hub Outer
(09608-06150) Bearing Cup Replacer
A241H
Drive Pinion Rear
(09608- 06180) Bearing Cup Replacer
A241H
Steering Worm
09612-65014 Bearing Puller
A241E, A243L
(09710-03160) (Remover)
A241H
Bearing Remover
09950-00030 Attachment
RECOMMENDED TOOL
EQUIPMENT
Part Name Note
Vernier caliper with depth gauge Check length of second coast brake piston rod.
Dial indicator with magnetic base Check piston stroke and end play of the output shaft.
Torque wrench
AKPPHELP.RU Руководство по ремонту АКПП
AX-15
AUTOMATIC TRANSAXLE - Preparation
LUBRICANT
Capacity
Item Classification
Liters US qts Imp. qts
(A241H)
Transfer left case × Differential lock control cover
Seal packing 1281, Transfer left case × Right case
Three bond 1281 or equivalent 08826-00090 Transfer left case × Inspection hole cover
Transaxle housing × Transfer assembly
Adhesive 1344,
Three bond 1344,
Loctite 242 or equivalent 08833-00080 Transaxle housing tighten bolts
Bolt 6- 6T
head No. 7- 7T No mark
4
8- 8T
9- 9T 4T
10- 10T
11- 11T
No mark 4T
Hexagon
flange bolt
No mark 4T Grooved
w/ washer
hexagon bolt
6T
Hexagon
head bolt Two
protruding 5T
lines
Hexagon
flange bolt Two
protruding 6T Welded bolt
w/ washer lines
hexagon bolt
Hexagon
head bolt Three
protruding 7T
lines
4T
Hexagon
head bolt Four
protruding 8T
lines
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IN-8
INTRODUCTION - Standard Bolt Torque Specifications
Specified torque
Diameter Pitch
Class mm mm Hexagon head bolt Hexagon flange bolt
N-m kgf-cm ft-lbf N-m kgf-cm ft-lbf
6 1 5 55 48 in.-lbf 6 60 52 in.-lbf
8 1.25 12.5 130 9 14 145 10
10 1.25 26 260 19 29 290 21
4T
12 1.25 47 480 35 53 540 39
14 1.5 74 760 55 84 850 61
16 1.5 115 1,150 83 - - -
6 1 8 80 69 in.-lbf 9 90 78 in.-lbf
8 1.25 19 195 14 21 210 15
10 1.25 39 400 29 44 440 32
6T
12 1.25 71 730 53 80 810 59
14 1.5 110 1,100 80 125 1,250 90
16 1.5 170 1,750 127 - - -
TRANSFER (A241H)
COMPONENTS
29 (300, 22)
Transfer Right Case
13 (130, 9)
Retainer
♦ O-Ring
♦ O-Ring
♦ Apply Gasket
Oil Strainer
Adjusting Nut
Lock Plate Lever Guide
Bearing Oil Pump
Adjusting Nut Driven Gear
Oil Reserver
Right Side Bearing
Outer Race
Transfer Right Case
44 (450, 33)
Dawel Pin
Plate Washer
♦ Apply Gasket
Extension Housing
♦ Apply Gasket
Dust Deflector
♦ Gasket Transfer Extension Housing
Drain Plug
69 (700, 51) ♦ O-Ring
39 (400, 29)
Transfer Left Case
♦ Oil Seal
25 (260, 19)
AT3351
AT3552
AT8480
AT3353
AT8113
AKPPHELP.RU Руководство по ремонту АКПП
TR-4
TRANSFER (A241H) - Removal of Component Parts
AT3354
5. CHECK PRELOAD
(a) Using SST and a spring tension gauge, measure
the driven pinion preload of the backlash be-
tween the driven pinion and ring gear.
SST 09326-2001 1
Driven pinion preload (at starting):
SST
8.8 - 13.7 N (0.9 - 1.4 kg, 2.0 - 3.1 Ib)
(b) Using SST and a spring tension gauge, measure
the total preload.
AT3360 SST 09326-201 1
Total preload (at starting):
Add driven pinion preload
4.9 - 8.8 N (0.5 - 0.9 kg, 1.1 - 2.0 Ib)
AT3362
AT3361
AKPPHELP.RU Руководство по ремонту АКПП
TR-5
TRANSFER (A241H) - Removal of Component Parts
AT3349
AT3350
AT8114
AT8092
AT4719
AKPPHELP.RU Руководство по ремонту АКПП
TR-6
TRANSFER (A241H) - Removal of Component Parts
AT7764
SST
AT3357
SST
AT3448
AKPPHELP.RU Руководство по ремонту АКПП
TR-7
TRANSFER (A241H) - Component Parts (Drive Pinion Bearing Cage)
Driven Pinion
Bearing Cage
Rear Side Bearing
♦ Lock Nut
♦ Transfer Pinion Spacer
Plug
♦ O-Ring
♦ Non-reusable part Oil Strainer AT3398
AT7765
AT7766
AKPPHELP.RU Руководство по ремонту АКПП
TR-8
TRANSFER (A241H) - Component Parts (Drive Pinion Bearing Cage)
AT7767
SST
AT7768
AT7769
AT8008
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TR-9
TRANSFER (A241H) - Component Parts (Drive Pinion Bearing Cage)
AT7770 AT7771
SST
AT7772
4. INSTALL SPACER
Install a new spacer to the driven pinion.
AT7773
AT7774
AT7775
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TR-10
TRANSFER (A241H) - Component Parts (Drive Pinion Bearing Cage)
AT7777
AKPPHELP.RU Руководство по ремонту АКПП
TR-1 1
TRANSFER (A241H) - Component Parts (Transfer Right Case Retainer)
Holder Bearing
AT3373
♦ Non-reusable part
AT8096
AT7781
AKPPHELP.RU Руководство по ремонту АКПП
TR-12
TRANSFER (A241H) - Component Parts (Transfer Right Case Retainer)
AT8009
AT7778
AT3342
AT7779
AT7780
AKPPHELP.RU Руководство по ремонту АКПП
TR-13
TRANSFER (A241H) - Component Parts (Transfer Right Case Retainer)
AT7778
AT8010
AT7781
AT3400
AT3402
AKPPHELP.RU Руководство по ремонту АКПП
TR-14
TRANSFER (A241H) - Component Parts (Transfer Right Case)
25 (250, 18)
Level Gauge Guide Plate
♦ O-Ring
10 (100, 7)
Oil Pump
10 (100, 7) Drive Rotor
Oil Pump
Driven Rotor
Oil Pump
Cover Compression Spring
Relief Valve
AT8063
AT8068
AKPPHELP.RU Руководство по ремонту АКПП
TR-15
TRANSFER (A241H) - Component Parts (Transfer Right Case)
AT8067
AT8046
AT8066
AT8046
Matchmarks
AT8080
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TR-16
TRANSFER (A241H) - Component Parts (Transfer Right Case)
AT8068
AT8063
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TRANSFER (A241H)
Руководство по ремонту АКПП
- Component Parts TR-17
(Ring Gear Mounting Case and Center Differential Case)
♦ Left Case
Bearing
Shaft Snap
Ring
97 (984, 71)
Shaft Snap
Ring
Spacer Differential Side
Right Gear
Conical Spring
Washer
Center Differential Case
Thrust Washer
Differential Pinion
Differential Pinion Thrust Washer
Differential Pinion Shaft
AT8294
AKPPHELP.RU
TRANSFER (A241H)
Руководство по ремонту АКПП
- Component Parts
TR-18
(Ring Gear Mounting Case and Center Differential Case)
AT7782
Matchmarks
AT7783
AT7784
Matchmarks
AT8295
SST
AT7785
AKPPHELP.RU
TRANSFER (A241H)
Руководство по ремонту АКПП
- Component Parts TR-19
(Ring Gear Mounting Case and Center Differential Case)
AT7786
AT7787
AT7788
AT7789
AKPPHELP.RU
TRANSFER (A241H)
Руководство по ремонту АКПП
- Component Parts
TR-20
(Ring Gear Mounting Case and Center Differential Case)
AT7790
AT8354
SST
AT7791
AT7792
AKPPHELP.RU
TRANSFER (A241H)
Руководство по ремонту АКПП
- Component Parts TR-21
(Ring Gear Mounting Case and Center Differential Case)
AT7793
AT7790
AT3310
AKPPHELP.RU
TRANSFER (A241H)
Руководство по ремонту АКПП
- Component Parts
TR-22
(Ring Gear Mounting Case and Center Differential Case)
(d) Using snap ring pliers, install the shaft snap ring.
AT7788
AT7795
AT7787
AKPPHELP.RU
TRANSFER (A241H)
Руководство по ремонту АКПП
- Component Parts TR-23
(Ring Gear Mounting Case and Center Differential Case)
AT7786
0.50
(0.0197)
0.40 Standard clearance
(0.0157)
AT7796
0.30
(0.0118)
0.20
(0.0079)
0.10
(0.0039)
AT7798
AT7787
AT7786
AT7799
AKPPHELP.RU
TRANSFER (A241H)
Руководство по ремонту АКПП
- Component Parts TR-25
(Ring Gear Mounting Case and Center Differential Case)
AT7800
AKPPHELP.RU Руководство по ремонту АКПП
TR-26
TRANSFER (A241H) - Component Parts (Transfer Left Case)
13 (130, 9)
Differential Control 7.1 (73, 63 in.-lbf)
Solenoid
♦ O-Ring
Straight Pin
Transfer Shift
Lever Shaft
♦ Oil Seal
Differential Control
Shift Fork
Differential Control
Shift Sleeve
♦ Spacer
Transfer
Differential Control Shift Lever
Shift Fork Shaft
Straight Pin
AT8011
AT8081
AT8085
AT8065
AT8060
AKPPHELP.RU Руководство по ремонту АКПП
TR-28
TRANSFER (A241H) - Component Parts (Transfer Left Case)
AT8054
AT8064
AT8243
5. REMOVE PLUGS
(a) Remove two plugs.
(b) Remove the O-rings from each plugs.
AT8244
AT8245
AKPPHELP.RU Руководство по ремонту АКПП
TR-29
TRANSFER (A241H) - Component Parts (Transfer Left Case)
AT8256
AT8257
AT8259
Seal Packing (c) Apply seal packing to the rear cover as shown.
Seal packing: Part No. 08826 - 00090 THREE BOND
1281, or equivalent
HINT: Install the cover as soon as the seal packing is ap-
plied.
AT3311
AKPPHELP.RU Руководство по ремонту АКПП
TR-30
TRANSFER (A241H) - Component Parts (Transfer Left Case)
AT8245
2. INSTALL PLUGS
(a) Coat the O-rings with ATF, and install it on to the
plugs.
(b) Install the two plugs.
AT8244
AT3401
AT8260
AT8251
AKPPHELP.RU Руководство по ремонту АКПП
TR-31
TRANSFER (A241H) - Component Parts (Transfer Left Case)
AT8252
AT8253
AT8266
AT8254
AT8255
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TR-32
TRANSFER (A241H) - Component Parts (Transfer Left Case)
AT8115
AT8267
AT8268
Adjusting Nut (b) Install the bearing adjusting nut and oil reserver,
until it touch the outer race.
Oil Reserver
AT4720
AT8353
AKPPHELP.RU Руководство по ремонту АКПП
TR-33
TRANSFER (A241H) - Component Parts (Transfer Left Case)
AT3362
AT3363
AT3361
AT3308
AT3358
AT3359
AKPPHELP.RU Руководство по ремонту АКПП
TR-35
TRANSFER (A241H) - Component Parts (Transfer Left Case)
Proper Contact
AT3361
AT3363
AKPPHELP.RU Руководство по ремонту АКПП
TR-36
TRANSFER (A241H) - Component Parts (Transfer Left Case)
AT3362
AT3357 SST
AT3415
AT8115
AT8267
AKPPHELP.RU Руководство по ремонту АКПП
TR-37
TRANSFER (A241H) - Component Parts (Transfer Left Case)
AT3362
AT3363
AT3309
AT8114
AT3450
AKPPHELP.RU Руководство по ремонту АКПП
TR-38
TRANSFER (A241H) - Component Parts (Transfer Left Case)
AT3361
AT3312
AT3356
AT3354
AT8113
AKPPHELP.RU Руководство по ремонту АКПП
TR-39
TRANSFER (A241H) - Component Parts (Transfer Left Case)
AT3353
AT8269
AT3352
AT3351