ECU DATSUN PICK-UP 1977 Workshop Manual

ST23860000

TM442

Fig
MT
42

l
talling

counte
haft

drive

gear

Available
counter
drive

gear
map
ring

No
Thickness
mm
in

I

2

3
1

4
0
055

1

5
0
059

1
6
0
063

II

TM366

Fig
MT
43

Installing
nap
ring

5
Press
countershaft
front

bearing

onto
countershaft
with
Drift
C

ST22360002
See

Figure
MT
44

ST22360002

KV3
II

00400

TM443

Fig
MT
44
Installing

counte
haft

front
bearing
Manual
Transmission

6

Support
adapter
plate
in

a
vise

with

Setting
Plate

Adapter

ST238
10001
with
mainshaft

facing

down

7
Install

mainshaft
reverse

gear

plain
washer

on
the
rear
of
mainshaft

and
install
mainshaft
nut

Tighten
mainshaft
nut

temporarily

8
Install

counter
reverse

gear
on
the

rear
of

countershaft
and
secure
with

map
ring

Use

snap
ring
to

give
a
minimum

gear
end

play
See

Figure
MT
45

No
Thickness
mm
in

I

2

3
1
4
0
055

1
5
0
059

1

6
0
063

o
TM361

Fig
MT
45

Imtalling
counter
reverse

gear

nap
ring

9
Install
reverse
idler

gear
on
re

verse
idler
shaft

10
With
1st
and
2nd

gears

doubly

engaged
tighten
mainshaft
nut
to
the

converted

torque
Cn
See

Figure

MT
48

using
Wrench
ST22520000

See

Figure
MT
4
7

ST22520000

TM768

Fig
MT
46

Tightening
mainshaft
nut

MTll
Explanation
of
converted

torque

Mainshaft
nut
should
be

tightened

to
14
to
17

kg
m
101
to

123
ft
lb

torque
with

the
aid
of

Wrench

ST22520000
When
doing
so
the

amount
of

torque
to
be

read
on

wrench
needle
should
be
modified

according
to
the

following
formula

L

C

kg
m
14
x
to

L

O
lO

L

17
x

L

0
10

or

L

C
ft
lb

101
x

L
0
33
to

L

123
x

L
0
33

Where

C
Value
read
on
the

torque
wrench

kg
m

ft
lb

L
Effective

length
of

torque

wrench
m
ft

ST22520000

Torque
wrench

Lm
ft
c

h

I

O
IOm

0
33
ft
TM587

Fig
MT
47

Setting
wrench

Example

When
a
0
40

m
1
31
ft

long
tor

que
wrench
is
used
the
Cn
in

Figure
MT
48
will
be
11
2
to
13
6

kg
m
81
to
98
ft
lb

I

Upper
limit
line

I

r

6
1

f
fdl

13
Converted

torque

90

I

Lower

limit
line

80

11

70
10

V
S
s

15

110

15

c

u

c

c

9

S

c

o

C

U
100
14

9

0
2
0
3

1
0
0
4
Manual

Transmission

0
5

0
6

2
0
0
7
0
8
m

2
5
It
1
5

L

Effective

length
of

torque
wrench

Fig
MT
48
CO
1Vert

d

torque

11

Tighten
mainshaft

nut
to

14
0

to
17
0

kg
m
101

to
123

ft
lb

torque
and
stake

mainshaft
nut
to

groove
of
main
shaft

with
a

punch
See

Figure
MT49

TM362

Fig
MT
49

Staking

mai
haft
nut

12
Measure

gear
end

play
and
back

lash

Make
sure
that

they
are
held
within

the

specified
values

For
details
refer

to
the
instructions

under

topic
Inspection
Note
The
main
drive

gear
and
coun

ter

driVe

gear
should
be
handled
as

a
matched

set

When

you
replace
a
main
drive

gear

or
counter

drive

gear
be
sure
to

replace
as
a
set
of

main
drive

gear

and
counter

drive

gear

ShUt
fork
nd

fork
rod

mbly

I

Place
1st
2nd
shift
fork
in

groove
in
1st

2nd

coupling
sleeve

and
slide
1st
2nd
fork
rod

through

adapter
plate
and

1st
2nd
shift

fork

Prior

to

installing
1st
2nd
fork

rod

install

3rd
4th
shift

fork
in

groove
in

3rd
4th

coupling
sleeve

Note
Shift

forks
for
1st
2nd
and

3rd
4th

are
one
and
the

same

parts

Make
sure
that
the

long
end
of
shift

fork
for

lot
2nd
is

placed
on
the

counter

gear
side
and
the

long
end

for
3rd
4th
is
on
the

e

side

MT12
Secure
1st

2nd
fork
rod
to

shift

fork
with

a
new

retaining
pin

2
Install
check

ball
check
ball

spring
and
check

ball

plug
Prior

to

tightening
check
ball

plug

apply

sealant
to
check
ball

plug

Align
notch
in

1st
2nd
fork
rod

with
check
ball

See

Figure
MT
50

TM367

Fig
MT

50

l
talling
1st
2nd

fork
rod

3
Slide

3rd
4th
fork
rod

through

adapter
plate
and
3rd

4th
shift
fork

and
secure
with
a
new

retaining
pin

Note
Prior
to

a

mbling
3rd
4th

fork
rod
install

two
2

interlock

balls
into

dap
er

plat
own
in

Figure
MT
16

4
Install
check
ball
and
check
ball

spring

Apply
sealant
to
check

ball

plug

and
install
it
in

place

Align
notch
in

3rd
4th
fork

rod

with
check
ball

by

sliding
3rd
4th

fork
rod
as

necessary
See
Figure

MT51

TM368

Fig
MT
51
Installing
3rd
4th

fork
rod

5

Place
reverse
shift
fork
in

reverse

idler

gear

Slide
reverse
fork
rod

through
re

verse
shift
fork
and

adapter
plate
and

secure
with
a
new

retaining
pin

5

Apply
a

light
coat

of
multi

purpose
grease
to

withdrawal
lever

release

bearing
and

bearing
sleeve
in

stall
them
on
clutch

housing

After

connecting
them

with
holder

spring
instaU
dust

cover
on
clutch

housing

6
Install
control
lever

temporarily

and

shift
control

lever

through
all

gears
to
make

sure

that

gears

opera
Ie

smoothly

Note
Install

drain

plug
and
filler

plug

ith
sealant
in

place
Manual

Transmission

INSTALLATION

Install
the
transmission
in
the
reo

verse
order
uf
removal

paying
atten

tion

to
the

following

points

1
Before

installing
dean

mating

surfaces
of

engine
rear

plate
and

trans

mission
case

2

Before

installing
lightly
apply

grease
to

spline
parts
of
clutch
disc

and
main
drive

gear

3

Tighten
bolts

securing
trans

mission

to

engine
to

specifications
See

Figure
MT
55

5
SPEED
TRANSMISSION

TYPE

DESCRIPTION

REMOVAL

DISASSEMBL
Y

TRANSMISSION
CASE
DISASSEMBLY

DISASSEMBL
Y
OF
GEAR

ASSEMBLY

REAR

EXTENSION
DISASSEMBLY

ADAPTER
PLATE

DISASSEMBLY

INSPECTION

TRANSMISSION
CASE
AND
REAR

EXTENSION
HOUSING

DESCRIPTION

The
transmission

is
of
a
5

speed

forward
with
overdrive
4

OD

speed

fully
synchronized
constant

mesh

type
that

uses
helical

gears

The
5

speed
transmission
covered
in

this
section
is

similar
in

all

respects
to

the
4

speed
transmission

type

F4W71B
stated

previously
except
the
CONTENTS

MT14

MT17

MT17

MT17

MT17

MT18

MT19

MT19
4
4

to
5
9

kg
m

32
to
43
ft
Ib

1

0
9
to
1
2

kg
m

7
to
9
rt
lb
TM773

Fig
MT
55

Tightening
torque

4
Remove
filler

plug
and
fIll
trans

mission
with
recommended

gear
oil

to

the
level
of
the

plug
hole

Approxi

mately
I
7

liters
3

pt
3

pt

FS5W71B

BEARING

GEARS

AND
SHAFTS

BAULK

RING

OIL

SEAL

ASSEMBL
Y

FRONT
COVER
ASSEMBLY

REAR

EXTENSION

ASSEMBLY

GEAR

ASSEMBLY

TRANSMISSION
ASSEMBLY

INSTALLATION
MT19

overdrive

position
of
it

The

overdrive

gear
rides
on
the

mainshaft

freely
through
the

needle

roller

bearing
and
counter

overdrive

gear
is
fitted
to
the

countershaft

by

splines

The
overdrive

synchronizer
system

is

on
the
mainshaft
rear
side

MT14
MT19

MT19

MT19

MT19

MT19

MT19

MT19

MT19

MT

20

MT20

Placing
the
control
lever
in

over

drive

position
brings
the
reverse
OD

coupling
sleeve
reverse

gear
on
main

shaft
into
mesh
with
overdrive
clutch

gear
The
reverse
OD

synchronizer

hub
is

fItted

to
the
mainshaft

by

splines
so
the
overdrive

gear
on
main

shaft

turns

together
with
the
main

shaft

Automatic
Transmission

REMOVAL
AND
INSTALLATION

TRANSMISSION
ASSEMBLY

REMOVAL

INSTALLATION

TRANSMISSION

ASSEMBLY

When

dismounting
the
automatic

transmission
from

a
vehicle

pay
at

tention
to
the

following
points

1

Before

dismounting
the
trans

mission

rigidly
inspecl
it

by
aid
of
the

Troubleshooting
Chart
and
dis

mount
it

only
when
considered
to
be

necessary

2
Dismount
the
transmission
with

utmost

care
and

when

mounting

observe
the

tightening

torque
indi

cated
on
another
table
not
to
exert

excessive
force

REMOVAL

In

dismounting
automatic
transmis

sion
from
vehicle

proceed
as
follows

I

Disconnect

battery
ground
cable

from
terminal

2

Disengage
torsion
shaft
from
ac

celerator

linkage

3
Jack

up
vehicle
and

support
its

weight
on

safety
stands
Recommend
a

hydraulic
hoist
or

open
pit
be
utilized

if
available

Make
sure
that

safety
is
insured

4
Remove

propeller
shaft

Note

Plug
up
the

opening
in
the
rear

extension
to

prevent
oil
from

flowing
out

5
Disconnect
front
exhaust
tube

6

Disconnect
selector

range
lever

from
manual
shaft

7

Disconnect
wire

connections
at

inhibitor
switch
CONTENTS

AT
33

AT
33

AT

33
TRANSMISSION
CONTROL
LINKAGE

REMOVAL
AND
INSTALLATION

ADJUSTMENT
AT
35

AT
35

AT
35

8
Disconnect
vacuum
tube

from

vacuum

diaphragm
and
wire

connee

lions

at
downshift
solenoid

9
Disconnect

speedometer
cable

from

rear
extension

10
Disconnect
oil

charging
pipe

II
Disconnect
oil
cooler
inlet
and

outlet
tubes
at
transmission

case

12

Support
engine
by
locating
a

jack
under

oil

pan
with
a
wooden

block
used
between

oil

pan
and

jack

Support
transmission

by
means
of
a

transmission

jack

13
Detach
converter

housing
dust

cover
Remove

bolts

securing
torque

converter
to
drive

plate
See

Figure

AT
4

AT261

Fig
AT
47

Removing
torque
conv
rter

attaching
bolts

Note
Before

removing
torque
con

verter
scribe
match
marks
on

two

parts
so
that

they
may
be

replaced
in
their

original
posi

tions
at

assembly

14
Remove
rear

engine
mount

securing
bolts
and
crossmember

mounting
bolts

15
Remove

starter
motor

16
Remove
bolts
securing
transmis

sion
to

engine
After
removing
these

AT
33
bolts

support
engine
and
transmission

with

jack
and
lower
the

jack
gradually

until
transmission
can
be
removed
and

take
out
transmission
under
the
car

Note

Plug

up
the

opening
such
as
oil

charging
pipe
oil
cooler
tubes

etc

INSTALLATION

Installation
of
automatic
transmis

sion
on
vehicle
is

reverse
order
of

removal
However
observe
the
follow

ing
installation
notes

Drive

plate
runout

Turn
crankshaft
one
full
turn
and

measure
drive

plate
mnou
t
with

indi

cating
finger
of
a
dial

gauge
rested

against
plate
See

Figure
AT
48

Replace
drive

plate
if

in
excess

of

0
5
mm
0

020
in

Maximum

allowable
mnout

0
3

mm
0
012
in

A
T262

Fig
AT
48
MeCJ
uring
drive

plate

runout

2
Installation
of
torque
converter

Line

up
notch
in

torque
converter

with
that
in
oil

pump
Be
extremely

careful
not
to
cause
undue
stresses
in

parts
in

installing

torq
e
converter

See

Figure
AT
49

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