brake DATSUN PICK-UP 1977 Owner's Guide

0
RANGE
KICKOOWN
Automatic
Transmission

f

r

t
While

operating
at

speeds
below

appruximately
80
to
90

kmfh
50
to

55
MPII
a
kick
3rd
2nd
downshift

an
be

accomplished
by
fully
de

pressing
the
accelerator

A
kick
3rd
lst
or

2nd
lst

downshift

can
also
be

accomplished

below

approximately
40
to
50

kmfh

25

to
30
MPII

When
kickdown
is

performed
the

push
rod

operates
by
the
solenoid
the

valve
is

depressed
downward
and
the

circuit
from
the

hne

pressure
7
to

the
hne

pressure
13
opens
The
h
e

press
e
13
3

plus
the
force
of
the

2nd
3rd
shift
valve

spring

oppose

the

governor
pressure
15
at

thc

2nd
3rd
shift
valve

@
and

thus

performs
3rd
2nd
downshift

op

eration

Moreover

the
hne

pressure
13

plus
the
force
of
the
lst
2nd
shift

valve

spring
oppose
the

governor
pres

sure
15
at
the
I

st
2nd
shift
valve

ID
and
thus

perform
3rd
2nd
or

2nd
st

downshift

operation
f
Cur
Clutch

La
Band
servo
On

Parll
lnl

Ran
e
rf
ltr5e
w

pawl

nUo

Fronl
Rear
brake
Opcullon
Release

clutch

Park
on
on

Reverse
2
82
on
on
on

Neutral

Dt
low
2458
on
on

Drive
02
cond
1
458
on
on

D

Top
t
ooo
on
on
on
on

2
Second
1458
on
on

12
Second
1
458
on
on

t

tl
low
2
4

8
on
on

AT
26

2
RANGE
2ND

GEAR
Automatic
Transmission

In
2

range
the

gear
rario
is

IOI
keJ

III
the
2nd

forward

speed
In

this
case

the
rear

dutch
is

engaged
and
the

band

brake
holds

the
front

clutch
drum
the

connecting
shell
and
sun

gear
from

rotating

The

power
flow
takes

place

through

the

input
shaft
inlo

the

rear
clutch

and

the
front
internal

gear
With
Ihe

sun

gear
held

stationary
the
front

planetary

gears
rotate
around

the
sun

gear
carrying
the

front

planet
carrier

with
them
The
front

planet
carrier

being
splined
to
the

output
shaft

causes
clockwise
rotation

of
the
OUI

put
shaft
at
a

reduced

speed

compared

to
the

speed
of
the

input
shaft
with

an
increase
in

torque
As
the
low
and

reverse

brake
is
not

engaged
the
clock

wise

rotation
of

the

output
shaft

causes
clockwise
rotation

of
fear
inter

nal

gear
and

the
rear

planet
carrier
also

rotates
around

the

sun

gear
in
a

clockwise

direction
The

one

way

clutch

will
act

to
allow

clockwise

rotation
of

connecting
drum

When
the

manual
valve

V
is

posi

tioned
at
2

the
line

pressure
7
is

introduced
into

the
line

pressure
cir

cuits
I
2

and
4

The

line

pressure

I
is
led

to

the

governor
rear
clutch

and

I
st

2nd
shift
valve

CID
as
in
the

case
of

D

range
The

line

pressure

2
locks

the
second
lock

valve

@and

is
led
to

thc

tightening
side
of
Ihe

band

servo

The

2nd

gear
is

therefore
fixed

regardless
of
vehicle

speed
When

DJ

range
3rd

gear
is

shifted
to
2

range
the

line

pressure
4
enters
Ihe

throttle

back

up
valve

V
and

produces

a

high
pressure
in
the
circuit
17

increasing
thc

throttle

pressure
li
6

The

line

pressure
7

is

therefore

increased

and

quickly
tightens
the

band

N

e

DJ
range
3rd

gear
to
2

range

If

DJ

range
3rd

gear
is

shifled

to
2

range

during
operation
the

manual
valve

V
is
also
shifted

to
A

T078

Fig
AT

40
Powu

tTansminion
during
2
H

range

A
1079

Fig
AT
41

Operation

of
each
mechanism

during
2

range

Clutch
Low

Band
ser
o
On

Parking
Gw

Ran8t

utio
w

pa

Front
Rear

brake
Operalion
Release

dutch

Pui
on

on

Revtrs
e

2
182
on

on
on

Neutral

01
Low

2
458
on
on

Drive
02
Second

1
458
Oft
Oft

OJ

Top
1
000
on
on

on
on

1
Second

1
458

on
Oft

12
tocond
1458

on
on

J

tt
Low
2
458

on
on

2

position

causing
the
line

pres

sure
circuit
3
to

be
drained

Therefore
the

line

pressure
circuit

10
which
is

situated
at
the

release

side
of
the
front
clutch

and
servo
is

also

drained

through
the
2nd

3rd

shift
val

e
@

forcing
the

speed
to

AT
28
decrease
from
3rd

gear
to
2nd

gear
In

this
case

the

speed

change

quickly
takes

place
because
the
line

pressure
7

and
other

pressure
are

heightened
by
the
action
of
the
line

pressure
4
in

the
same

manner
as

described
under
2

range

1
RANGE

LOW
GEAR
Automatic

Transmission

f
Wilen

slJrting
in
I

range
the

drlvlIlg
gear
is
IOl
ked

to

the
low

gear

fJIIIJ

In
H

range
the

rear

clutch
is

engJged
and

the
low
and
reverse
brake

hulds
he

onnecting
drum
and

feac

planet
carrier
from

rotating
The

power
tlow
lakes

place
through
the

input
shaft
and
into
lhe
rear

clutch

ROlalion

of
the
rear
clutch

drives
lhe

rear
dutch
hub

and
front
internal

gear

The
front

internal

gear
rotates
the

front

planetary
gears
clockwise
to

cause
the

sun

gear
to

rotate
counter

clockwise

Counterclockwise

rotation

of
the

sun

gear
turns
the
rear

planetary
gear

clockwise

The

rear

planet
carrier

splined
to

the

connecting
drum
is
held

from

rotating
by
the

low
and

reverse
brake

The

clockwise
rotation

of
the
rear

planetary

gears
therefore

rotates
the

rear

internal

gear
and

internal

drive

tlange
The

internal
drive

tlange
is

splined
to

the

output
shaft
and
rotates

the

uutput
shaft
clockwise
However

the

output
shaft
rotates

at
a

lower

speed

compared
to
that

of
the

input

shaft

This
is

caused

by
the
fact

Ihat

the

front

planet
carrier

rotates
at

the

same

speed
as
Ihe

OUlput
shaft
in
the

same
direction

since
the
carrier

is

splined
to

the

output
shaft
The
front

internal

gear
and

planetary
gear
assem

bly
are

rotating
in

the

same
direction

but

the

planet
carrier
is

rotating
at

a

speed
slower
than
the

ring

gear
So
the

gear
ralio

of
this

speed
range
is

a

combination
of
the
ratios

provided

by

the
front

and
rear

planetary
gear
as

semblies

When
the

manual
valve

Vis

posi

tioned

at
I

the
line

pressure
7

is

applied
into

the
line

pressure
circuits

I

4

and
5
The
oil

pressure
in
5

actuates
the
luw

and

reverse
brake

after

being
introduced
into

the
circuit

12

through
Ihe

1st
2nd
shift

valve

ID
and

the

line

pressure
I

acts
on
C

A

T076

Fig
AT

43
Power

transmission

during
1
J

range

Fai1

A

TOn

Fig
AT
44

Operation

of
each
mechanism

during
JJ
range

Clutch
Low

Band
servo
On

Parking
Gm

Range
reverse
w

pawl
ratIO

Front
Rur

brake
Operatlon
Release

clulCh

Park

on

on

Reverse
2
182
on
on

on

Neutral

01
low

2
458
on

on

Drive
02
Second

1
458
on
on

03

Top
1000
on
on
on

on

2
Second

1
458
on

on

2
Second

IAS8
on

on

I

1
low
2
458
on
on

the

rear
clutch
and

governor
The

line

pressure
4

acts
in

the
same
manner

as

in
2

range

Similar
to

that
of
the

D

range

the
line

pressure

inr
reases
with
the

degree
of
accelerator

pedal

depression

and
the
line

pressure
decreases
with

the

increase
of
car

speed
The

governor
pressure
15
which
acts

on
the

I

st
2nd
shift
valve
does
not
increase

until
it

overcomes
the

combined
force

of
the
line

pressure
12
and
the

spring

causing
no
st
2nd

speed

cha

nge

AT
30

Starter

should
be

brought
into

op

eration

only
when
selector

lever
is
in

P

and
N

positions
it

should
not

be
started

when
lever
is
in
D
2

I

and
R

positions

Back

up
lamp
should
also

light

when

selector
lever
is

placed
in

R

position

S
After

converter
is
installed

rotate

10

Check
level
of
oil
in
transmis

crankshaft
several
turns
and
check

to

be
sure
that
transmission

rotates

freely
sion

For
detailed

procedure
see

page

AT48

without

binding

6
Pour

recommended
automatic
II

Move
selector
lever

through
aU

positions
to
be

sure
that
transmission

transmission

fluid

up
to
correct
level

operates
correctly

through
oil

charge
pipe

verter
to
transmission
measure

dis

With
hand

brake

applied
rotate

tan
A

to
be
certain

that

they
are
7

Connect
manual
lever
to
shift

engine
at

idling
Without

disturbing

correctly
mbi
d

S
F
rod

Opeiationsliould
oecaTrie
f
bue

the
above

sclUng
ffiovTSelector
lever

AT

50
with

manual
and
selector
levers
in

through
N

to
D
to
2

to
I

Distance
A
N

and
to
R
A

slight
shock
should
be

More
than
21

5
mm
0
846
in
8
Connect

inhibitor
switch
wires

felt

by
hand

gripping
selector

each

time
transmission
is
shifted
Automatic
Transmission

4
Bolt
converter
to
drive

plate

Note

Align
chalk
marks

painted
a

cross
both

parts
during
disas

sembling

processes

AT116

Fig
AT
49

Torque
converter

aligning
cu
t

3
When

connecting

torque
can

A

ATl17
Notes

a
Refer
to

covering
topic

under

Checking
and

adjusting

inhibitor
switch
n

on

page

AT
49

b

Inspect
and

adjust
switch
as

above
whenever
it
has
to

be

removed
for
service

Fig
AT
50

Installing

torque
converter
9
Check
inhibitor
switch
for

op

eration

AT
34
Note

See

page
AT

49
for

checking

engine
idling

12

Check

to
be

sure
that
line

pres

sure
is

correct
To
do
this

refer
to

relative

topic
under

Testing
line

pres

sure
on

page
AT

52

13

Perform

stall

test
as

per
the

instructions

on

page
AT

50

Automatic

Transmission

MAJOR

REPAIR

OPERATION

SERVICE
NOTICE
FOR

DISASSEMBLY

AND

ASSEMBLY

TORQUE
CONVERTER

INSPECTION

TRANSMISSION

DISASSEMBL
Y

INSPECTION

ASSEMBL
Y

SERVICE
NOTICE

FOR
DISASSEMBLY

AND
ASSEMBLY

I
It

is
advisable

that

repair
opera

tions
be

carried
out
in
a

dust

proof

room

2
Due

to
the
differences
of
the

engine
capacities
the

specifications
of

component

parts
for

each
model
s

transmission

may
be
different

They

do
however
have

common

adjust

ment

and

repair

procedures
as
well
as

cleaning
and

inspection

procedures

outlined
hereinafter

3

During
repair
operations
refer
to

Service
Data

and

Specifications
see

tion
for

the
correct

parts
for
each

model

4

Before

removing
any
of

subas

semblies

thoroughly
clean
the
outside

of
the

transmission
to

prevent
dirt

from

entering
the
mechanical

parts

5

Do
not
use
a
waste

rag
Use
a

nylon
or

paper
cloth

6
After

disassembling
wash
all
dis

assembled

parts
and
examine
them
to

see
if
there
are

any
worn

damaged
or

defective

parts
and
how

they
are

affected
Refer
to

Service
Data
for

the

extent
of

damage
that

justifies

replacement

7

As
a
rule

packings
seals
and

similar

parts
once
disassembled
should

be

replaced
with
new
ones

TORQUE

CONVERTER

The

torque
converter
is

a
welded

construction
and

can
not
be
disas

sembled
CONTENTS

AT

36

AT

36

AT

36

AT

36

AT

36

AT
38

AT

38
COMPONENT
PARTS

FRONT

CLUTCH

REAR

CLUTCH

LOW
REVERSE
BRAKE

SERVO

PISTON

GOVERNOR

OIL

PUMP

PLANETARY

CARRIER

CONTROL

VALVE
AT

40

AT
40

AT
41

AT
42

AT
42

AT
43

AT
43

AT
44

AT

44

INSPECTION
2

Remove
bolts

securing
converter

1

Check

torque
convertf

for

any
housing
to
transmission

case
Remove

sign
of

damage

bending
oil
leak

or
torque
converter

deformation

If

necessary
replace
3
Remove

speedometer
pinion

2

Remove
rust
from

pilots
and
sleeve

bolt
Withdraw

pinion

bosses

completely
4

Remove
downshift
solenoid
and

If

torque
converter
oil
is

fouled

or
vacuum

diaphragm
Do

not
leave
dia

contaminated
due
to
burnt
clutch

phragm
rod
at
this

stage
of
disas

flush
the

torque
converter
as
follows
sembly
Rod
is

assembled
in

top
of

vacuum

diaphragm
See

Figure

I
Drain
oil
in

torque
converter

AT

53

2
Pour

non
lead

gasoline
or

kero

sene
into

torque
converter

approxi

mately
0
5
liter

I
U
S

pt
U

Imp

pt

3

Blow
air

into

torque
converter

and

flush
and
drain

out

gasoline

4
Fill

torque
converter
with

torque
converter
oil

approximately

0
5
liter
I

V
S

pt
U

Imp
pt

5

Again
blow
air
into

torque
con

verter
and
drain

torque
converter
oil

TRANSMISSION

DISASSEMBLY

I

Drain
oil
from
the

end
of
rear

extension

Mount
transmission
on

Transmission
Case

Stand
ST07870000

or
ST07860000
Remove

oil

pan
See

Figure
AT
52

AT118

Fig
AT

52

Removing
oil

pan

AT

36
Fig
AT
53
Down

hilt
olenoid
and

vacuum

dilJphragm

5

Remove

bolts
which

hold
valve

body
to
transmission

case
See

Figure

AT
54

Fig
AT
54

Removing
valve

body

6
Loosen
lock
nut

@
on

piston

stem

D
as
shown
in

Figure
AT

55

Then

tighten

piston
stem
in

order
to

prevent
front
clutch

drum
from

falling

when
oil

pump
is
withdrawn

AT121

Fig
A
T
55
Loosenin
band
seruo

7
Pull
out

input
shaft

8
Withdraw
oil

pump
using
Sliding

Hammer
ST25850000
Do
not
allow

front
clutch
to
come
out
of

position

and

drop
onto
floor
See
Figure

AT
56

AT122

Fig
AT
56

Removing
oil

pump

9

Remove
band
strut
This
can
be

done

by
loosening
piston
stem
further

See

Figure
AT
57

Fig
AT

57
R

moving
band
strut

10
Remove
brake
band
front

clutch
and
rear
clutch
as
an
assembled

unit

11
Remove

connecting
shell

rear

clutch
hub
and
front

planetary
carrier

as
a
unit
See

Figure
AT
58
Automatic
Transmission

Ii

AT124

Fig
AT
58
R
mouin
connectin
shell

12
With

the
aid
of

Snap
Ring
Re

mover
HT69860000

pry
snap
ring
off

output
shaft

See

Figure
AT
59

Fig
AT
59
Remouing
sruzp
ring

13
Remove
connecting
drum
and

inner

gear
of

rear

planetary
carrier
as

an

assembly
See
Figure
AT
60

AT126

Fig
AT
60
Remouing
connecting

drum

14
Remove

snap
rings
and
then

remove
rear

planetary
carrier
internal

gear
connecting
drum
one

way
clutch

outer
race
and
one

way
clutch
in
that

oroer

15
Remove
rear
extension
by

loosening
securing
bolts
See

Figure

AT
61

AT
37
AT127

Fig
AT
61
Remouin
rear
extension

16
Pull
out

output
shaft
remove
oil

distributor

CV

together
with

governor

valve

CD
See

Figure
AT
62

Fig
AT

62

Remouinggouernorand

oil
distributor

17
Pry
off

snap
ring
using
a
pair
of

pliers
Remove

retaining
plate
drive

plate
driven

plate
and
dish

plate
in

that
order
See

Figure
AT
63

Fig
AT
63
Remouing
driue
and

driuen

plates

18
Reaching

through
back
side
of

transmission
case
remove
hex
head

slotted
bolts
as
shown
in

Figure

AT
64
To
do
this
use
Hex
head

Extension
ST25570001

ST25570000
One
way
clutch
inner

race
thrust
washer

piston
return

spring
and
thrUst

spring
ring
can
now

be
removed

I
i
0

t
V

iL

1

0

ST25570001

j

w
1
h

AT130

Fig
AT
64

Removing
hex
head
slotted

bolt

19
Blowout
low
and
reverse
brake

piston
by
directing
a

jet
of
air
into

holeJn
cylinder
See
F

igure
AT
65

Fig
AT
65

Removing
piston

20
Remove
band
servo

loosening

attaching
bolts

Note
If

difficulty
is
encountered
in

removing
retainer
direct
a

jet
of
air

toward
release
side

as
shown
in

Figure
AT
66

II

AP

fW
l

1

A
T132

Fig
AT
fiB

Removing
bond
servo

21

Pry
snap

rings
CD
from
both

ends
of

parking
brake
lever

@
and

remove
the
lever

Back
off
manual

shaft

lock
nut

ID
and
remove

manual

plale
@
and

parking
rod

CID
See

Figure
AT
67
Automatic
Transmission

Up

@
J1i

ll
J

t
i
p

lli
l
1

I
l
P
l

1
Ii

@

j
Y

L

l

rr
i

J

ry

j

AT133

Fig
AT
67

Removing
manual

plate

22
Remove
inhibitor
switch
and

manual
shaft

by

loosening
two
secur

ing
bolts

INSPECTION

Torque
c
onverter
housing

transmission
c
ase
and

rear
extension

I

Check
for

damage
or
cracking
if

necessary
replace

2

Check
for
dents
or
score
marks

on

mating
surfaces

Repair
as
nee

essary

3
If
rear
extension
bushing
is
worn

or
cracked
replace
it

as
an
assembly
of

bushing
and
rear
extension
housing

Gaskets
and
O

ring

1

Always
use
new

gaskets
when
the

units
are
to
be
disassembled

2
Check
O

rings
for
burrs
or
crack

ing
If

necessary
replace
with

new

rings

011
distributor

I
Check
for

signs
of
wear
on
seal

ring
and

ring
groove
replacing
with

new
ones
if
found
worn

beyond
use

Check
that
clearance
between
seal

ring
and

ring
groove
is
correct
If
out

of

specification
replace
whichever
is

worn

beyond
limits
Correct
clearance

is
from
0
04
to
0
16
mm
0
0016
to

0
0063
in
See

Figure
AT
68

AT
J8
j
Clearance

1

61
Seal

dng

0

j

J

I

I

AT134

ig
A
r
68
Me

q
sur

ingseal
r

ing
to

ring
groove
clearance

ASSEMBLY

Assembly
is
in

reverse
order
of

disassembly
However
observe
the
fol

lowing
assembly
notes

After

installing
piston
of
low
and

reverse
orake
assemble
thrust

spring

ring
return

spring
thrust
washer
and

one

way
clutch
inner
race

Torque

hex
head
slotted
bolt
to
L3to
1
8

kg
m

9
to
13
ft
ib

using
Hex
head
Ex

tension
ST2SS7000
ST2SS70000

Torque
Wrench
GG93010000
and

Socket
Extension
ST2S490000

ST2SS
12001
See
Figure
AT
69

ST2557000t

ST25490000

I

GG930JOOOO

A
T135

Fig
AT
69

Installing
ont

woy
clutch

inner
race

2
After
low
and
reverse
brake
has

been
assembled
measure
the
clearance

between

snap
ring
CD
and

retaining

plate
@
Select

proper
thickness
of

retaining
plate
to

give
correct

ring
to

plate
clearance
See

Figure
AT
70

Low

and
reverse
brake

clearance

0
80
to
1

05
rom

0
0315
to
0
0413
in

Fig
AT
70

Measuring
ring
to

plate

clearance

Available

retaining
plate

Thickness
mm
in

1l
8
0
465

12
0

0472

12
2
0480

124

0488

12

6
0496

12

8
0
504

For

inspection
procedure
for

low

and

reverse
brake
see

page
AT
42
for

Assembly

3

Install
one

way
clutch
so
that
the

arrow
mark
is
toward
front

of

vehicle
It
should
be

free
to

rotate

only
in

clockwise
direction
See
Figure

AT
71

mITIJ

o

oml

AT137

Fig
AT
71

One

way
clutch

4
After

installing
rear
extension

torque
attaching
bolts
to
2
0
to
2
5

kg
m

14
to
18
ft
lb
Place
manual

lever
in
P

range
and
check
to

be
sure

that
rear

output
shaft
is

securely

blocked

5

Tighten
servo
retainer

temporari

ly
at
this

stage
of

assembly

6
Place

rear
clutch

assembly
with

needle

bearing
on
front
assembly
Automatic
Transmission

7

Install
rear
clutch
hub
and
front

planetary
carrier
as
shown
in

Figure

AT
72

AT142

Fig
AT
72

Installing
planetary
carrier

8
Assemble

connecting
shell
and

other

parts
up
to
front
Clutch
in

reverse
order
of

disassembly

AT143

Fig
AT
73
Installing
connecting
shell

9

Adjust
total
end

play
and

front

end

playas
follows

Front
end

play

L

r

L

CD
I

r

L

11
I
J

Total
end

play
@

Front
clutch

thrust
washer

2

Oil

pump
cover

3
Front
clutch

4

Rear
clutch
AT138

5

Trammission
case

6
Oil
pump

gasket

7
Oil

pump
cover

bearing
race

Fig
AT
74
End

play

1
Measure
the
distance
A

and

C

by
vernier

calipers
as
shown

in

Figure
AT
75

AT
39
i
Rear

c

clutch

N
edle
bearing

Bearing
race

I

Fig
AT
75
AT139

Measuring
the
distance

A

and
C

2

Measure
the
distance
B

and

D
of

oil

pump
cover
as
shown
in

Figure
AT
76

I

L

I
Oiipi
mp

AT140

Fig
AT
76

Measuring
the
distance

B
and
D

Adjustment
of

total
end

play

Select
oil

pump
cover

bearing
race

by

calculating
the

following
formula

TT
A
B
W

where

T

T
Required
thickness
of
oil

pump

cover

bearing
race
mm
in

A

Measured
distance
A
mm
in

B
Measured
distance
B
mm

in

W
Thickness
of

bearing
race

temporarily
inserted
mm
in

Available
oil

pump
cover

bearing

race

Thickness
mm

in

1
2
0
047

I
4
0
055

1
6
0
063

1
8
0
071

2

0
0
079

2
2
0
087

Specified
total
end

play

0
25100
50
mm

0
0098
to
0
0197
in

Adjustment
of
front
end

play

Sele
t
front
dutch
thrust
washer

by

calculating
the

following
formula

T

F
C
D

0
2
mm

where

T

F
Required
thickness
of
front

clutch
thrust
washer
mm
in

C
Measured
distance
C
mm
in

D
Measured
distance
D
mm
in

Available
front
clutch
thrust

washer

Thickness
mm
in

1
5
0
059

I
7
0
067

1
9
0
075

2
1
0
083

2
3
0
091

2
5
0
098

27
0
106

Specified
front
end

play

0
5
to
0

8
mm

0
020
to
0

031
in

Notes

a
Correct
thickness
of

bearing
race

and
thrust
washer
is
always
the
one

which
is
nearest
the
calculated
one

b
Installed
thickness
of
oil

pump
gas

ket
is
0
4

mm
0
016
in

10
Check
to
be
sure
that
brake

servo

piston
moves
freely
For
detailed

ptocedure
refer
to

page
AT
42
for

Servo
Piston
Use
care
to

prevent

piston
from

coming
out
of

place
dUI

ing
testing
since
servo
retainer
is
not

tightened
at
this

point
of

assembly

II
Make
sure
that
brake
band
strut

is

correctly
installcd

Torque
piston

stem
to
1
2
to
1
5

kg
m
9
to
11

f1
lb
Back
off
two
full
lurns
and

secure
with
lock
nut
Lock
nut

tight

ening
torque
is
1
5
to
4

0

kg
m

II
to

9

f1
lb
Automatic
Transmission

12
After
inhibitor
switch
is
in

stalled
check
to
be
sure
that
it

op

erates

properly
in

each
range
For

detailed

procedure
refer
to

page
AT

49
for
Checl
ing
and

Adjusting
Inhibi

tor
Switch

13
Check
the

length
L
between

case
end
to
rod
end
ofvacuum
throllle

valve
fully

pushed
in
Then
select

adequate
diaphragm
rod
of
corre

sponding
measured
length
See
Figure

AT
77

Available

diaphragm
rod

Distanl
e

measured
L
ITIm
in

Under25
55

l
OO59

25
65

to
26
05
1

0098
to
1
0256

26
15
to
26
55
1

0295
to
1

0453

26

65
to
27
05
1
0492
to
1

0650

Over
27
15
1
0689

COMPONENT
PARTS

The
transmission
cons
sts
of

many

small

parts
that
are

quite
alike
in

construction
yet
machined
to

very

close
tolerances
When
disassembling

parts
be
sure
to

place
them
in

order
in

part
rack
so

they
can

be
restored
in

the

unit
in
their

proper
positions
It
is

also

very
important
to

perform
func

tianal
test
whenever
it
is

designated

FRONT
CLUTCH

Disassembly

Front

clutch
drum

I

Pinon

lcz

t

AT146

1

Snap
ring

2

Retaining
plate

3
Drive

plate

4

Driven

plate

Fit
AT
78
S
Dished

plate

6

Snap

ring

7

Spring
retainer

8
Coil

spring

Sectional
view

of

front
clu
tch

AT
40
i

i
n
H

I
I

ni
c
A
i

iif

L

1

AT145

Fig
AT
77

Measuring
the
distance

L

Diaphragm
rod

length
mm
in

29
00
142
u

29

5
1161

30
0
1
81

30
5
1201

31
0
I
O

I

Pry
off

snap
ring
D
with

a

suitable
screwdriver
or

a

pair
of

pliers

Remove
a

retaining
plate
@
drive

plate
CID
driven

plate
@
and
dished

plate
@
in

the
order
listed
as
shown

in

Figure
AT
78

I

2

Compress
clutch

springs
using

Clutch

Spring
Compressor

ST25420001
or

51
25420000
Re

move

snap
ring
@
from

spring
re

tainer

using
Snap
Ring
Remover

ST2532000
I

See

Figure
AT
79

AT147

Fig
AT
79

Removing
snap
ring

Note
When
Clutch

Spring
Compres

sor
ST25420000
is
to
be
used
cut

the

toe

tips
of
three

legs
by
a

grinding
wheel
See

Figure
AT
80

3
Blowout

piston
by
directing
a

jet

of

air
into

hole
in

clutch
drum
See

Figure
AT

87

AT155
V

i

J
i

j

Fig
AT
87

Blowing
out

piston
Automatic
Transmission

1

w

Ai

I

i
1

i

3
j

P2

0

AT157

Fig
A
T
89

Testing
rear
C
U
tch

Inspectl

ioW
S
REVERSE
BRAKE

Refer
to

page
AT41
for

Inspection

of
Front
Clutch

Assembly

Assemble
in

reverse
the
order
of

disassembly
Dip
all

parts
in
clean

automatic
transmission
fluid
before

assembling
Note

that
the
number
of

drive
and
driven

plates
varies
with

type

of
vehicle
F
or
details
refer
to
Serv

ice
Data

Specifications

I

After
rear
clutch
is
assembled

check
to
be
sure
that
clearance
be

tween

snap
ring
D
and

retaining

plate

l
is
held
within

prescribed
toler

ances
See

Figure
AT
88

Specified
clearance

1

0
to
1
5
rom

0
039
to
0
059
in

AT156

Fig
AT
SS

Measuring
ring
to

plate

clearance

2

Testing
rear
clutch

Install
rear
clutch

on
oil

pump

cover

Blow

compressed
air

into
oil
hole

to
test
for
defInite

clutch

operation
as

shown
in

Figure
AT
89
Disassembly

1
Fllow

steps
as
described
in

page

AT

36
for
Transmission

Disassembly

2
mow
out

piston
by

directing
a

jet

of
air
into
oil
hole
in
clutch

piston

Inspection

I
Check
drive

plate
facing
for

wear

or

damage
if

necessary
replace
Refer

to

Service
Data

Specifications
for

tolerances

2
Test

piston
return

spring
for

weakness
Discard
if
weakened

beyond

use

3

Replace
faulty

parts
with
new

ones

Assembly

I

After
low
reverse

piston
is

installed
assemble
thrust

spring
ring

retum

spring
thrust
washer
and

one

way
clutch
inner

race

Using

Hex
head
Extension

ST25570001

ST25570000

torque
hex
head
slot

ted
bolt
I
3
to
1

8

kg
m
9
to
13

ft
lb

2
Insert
dished

plate
driven

plate

drive

plate
and

retaining

plate
into

transmission
case
in

that
order
Install

sn

p
ring
to
secure
the
installation

Note

The
number
of
drive
and
driven

plates
wries
with

type
of
vehicle

For
detailed
information

refer
to

Service
Data

Specifications

AT42
3

Without

disturbiilg
the
above

setting
check

to
be

sure
that

clearance

between

snap
ring
and

retaining
plate

is

within

specified
limits
If

necessary

use
other

plates
of
different
thickness

until
correct

clearance
is

obtained

Specified
clearance

0
80
to
1

05
rom

0
0315
to
0

0413
in

4

Blow

compressed
air
into

oil
hole

in

low
reverse
brake
to
test
for

definite
brake

operation
as
shown
in

Figure
AT

90

Fig
AT
90

Testing
low

reverse

brake

SERVO
PISTON

Disassembly

I
Blowout

piston
by
directing
a

jet

of
air
into

hole
in

release
side
of

piston

2
Remove

servo

piston
return

spring

Inspection

Check

piston
for
wear

damage
or

other
faults
which

might
interfere
with

proper
brake

operation

v

r
0

111

Ll
7

J

I

AT159

Fig
AT
91

Removing
pi3ton