torque converte clutch TOYOTA T100 1996 Factory Service Manual

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− INTRODUCTIONTERMS
1996 TOYOTA T100 (RM449U) HO2S
Heated Oxygen SensorHeated Oxygen Sensor (HO2S)
IACIdle Air ControlIdle Speed Control (ISC)
IATIntake Air TemperatureIntake or Inlet Air Temperature
ICMIgnition Control Module−
IFIIndirect Fuel InjectionIndirect Injection
IFSInertia Fuel−Shutoff−
ISCIdle Speed Control−
KSKnock SensorKnock Sensor
MAFMass Air FlowAir Flow Meter
MAPManifold Absolute PressureManifold Pressure
Intake Vacuum
MCMixture Control
Electric Bleed Air Control Valve (EBCV)
Mixture Control Valve (MCV)
Electric Air Control Valve (EACV)
MDPManifold Differential Pressure−
MFIMultiport Fuel InjectionElectronic Fuel Injection (EFI)
MILMalfunction Indicator LampCheck Engine Light
MSTManifold Surface Temperature−
MVZManifold Vacuum Zone−
NVRAMNon−Volatile Random Access Memory−
O2SOxygen SensorOxygen Sensor, O2 Sensor (O2S)
OBDOn−Board DiagnosticOn−Board Diagnostic (OBD)
OCOxidation Catalytic ConverterOxidation Catalyst Converter (OC), CCo
OPOpen LoopOpen Loop
PAIRPulsed Secondary Air InjectionAir Suction (AS)
PCMPowertrain Control Module−
PNPPark/Neutral Position−
PROMProgrammable Read Only Memory−
PSPPower Steering Pressure−
PTOXPeriodic Trap OxidizerDiesel Particulate Filter (DPF)
Diesel Particulate Trap (DPT)
RAMRandom Access MemoryRandom Access Memory (RAM)
RMRelay Module−
ROMRead Only MemoryRead Only Memory (ROM)
RPMEngine SpeedEngine Speed
SCSuperchargerSupercharger
SCBSupercharger Bypass−
SFISequential Multiport Fuel InjectionElectronic Fuel Injection (EFI), Sequential Injection
SPLSmoke Puff Limiter−
SRIService Reminder Indicator−
SRTSystem Readiness Test−
STScan Tool−
TBThrottle BodyThrottle Body
TBIThrottle Body Fuel InjectionSingle Point Injection
Central Fuel Injection (Ci)
TCTurbochargerTurbocharger
TCCTorque Converter ClutchTorque Converter

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− PREPARATIONAUTOMATIC TRANSMISSION
PP−77
1996 TOYOTA T100 (RM449U)
EQUIPMENT
OBD II scan tool
Ohmmeter
Voltmeter
Vernier calipersTorque converter clutch
Dial indicator or dial indicator with magnetic baseDrive plate
Straight edgeTorque converter clutch
Torque wrench

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− SERVICE SPECIFICATIONSAUTOMATIC TRANSMISSION
SS−51
1996 TOYOTA T100 (RM449U)
TORQUE SPECIFICATION
Part tightenedN·mkgf·cmft·lbf
Valve body x Transmission case101007
Oil strainer x Valve body (A340E)5.45548 in.·lbf
Oil strainer case x Valve body (A340F)101007
Oil strainer x Valve body (A340F)6.97061 in.·lbf
Oil pan7.47565 in.·lbf
Drain plug2020515
Parking lock pawl bracket x Transmission case7.47565 in.·lbf
Extension housing x Transmission case (A340E)3637027
Extension housing x Rear mounting insulator2525018
Rear support member x Rear mounting insulator (A340F)1818013
Rear support member x Body (A340F)9597070
Rear mounting insulator x Rear mounting bracket (A340E)1818013
Rear mounting bracket x Frame (A340E)5859042
Propeller shaft x Rear differential (A340E)7475054
Front propeller shaft x Front differential (A340F)7475054
Front propeller shaft x Transfer (A340F)7475054
Rear propeller shaft x Transfer (A340F)7475054
Rear propeller shaft x Rear differential (A340F)7475054
Center support bearing x Body3637027
Drive plate x Crankshaft8385061
Torque converter clutch x Drive plate4142030
Stiffener plate x Engine (A340F)3738027
Stiffener plate x Transmission3738027
Front exhaust pipe x Exhaust manifold6263046
Front exhaust pipe x TWC4849035
Rear support member x Dynamic damper6162044
Oil cooler pipe3435025
Transmission x Engine7173053
Rear end plate x Transmission3738027
Rear support member x Transfer under cover2930021
Cross shaft x Frame2829021
Cross shaft x Transmission131309
Cross shaft x No.1 gear shifting rod131309
Exhaust pipe clamp(3RZ−FE)1919514
Exhaust pipe support bracket x Transmission (3RZ−FE)7173053
Exhaust pipe support bracket x Transmission (5VZ−FE)4445033
Exhaust pipe support bracket x Exhaust pipe (5VZ−FE)4445033
Park/neutral position switch (Nut)3.94035 in.·lbf
Park/neutral position switch (Bolt)131309
No.2 vehicle speed sensor5.45548 in.·lbf
Speedometer driven gear sleeve x Locking plate1616012
ATF temperature sensor x Transmission1515011
Shift lever assembly x Steering column assembly2930022

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DI−269
1996 TOYOTA T100 (RM449U)
4. ROAD TEST
NOTICE:
Perform the test at normal operating ATF temperature 50 − 80°C (122 − 176°F).
(a) D position test
Shift into the D position and fully depress the accelerator pedal and and check the following points:
(1) Check up−shift operation.
1 → 2, 2 → 3 and 3 → O/D up−shift takes place, at the shift point shown in the automatic shift
schedule (See page SS−49).
HINT:
There is no O/D up−shift or lock−up when the coolant temperature is below 60°C (140°F).
Evaluation:
ProblemPossible cause
If there is no 1→2 up−shiftShift solenoid valve No.2 is stuck
1−2 shift valve is stuck
If there is no 2 →3 up−shiftShift solenoid valve No.1 is stuck
2−3 shift valve is stuck
If there is no 3 →O/D up−shift3−4 shift valve is stuck
If the shift point is defectiveThrottle valve, 1−2 shift valve, 2−3 shift valve, etc. are defective
If the lock up is defectiveShift solenoid valve SL is stuck
Lock−up relay valve is stuck
(2) Check for shift shock and slip.
Check for shock and slip at the 1 → 2, 2 → 3 and 3 → O/D up−shifts.
Evaluation:
ProblemPossible cause
If the shock is excessive
Line pressure is too high
Accumulator is defective
Check ball is defective
(3) Check for abnormal noises and vibration.
Run at the D position lock−up or O/D gear and check for abnormal noises and vibration.
HINT:
The check for the cause of abnormal noises and vibration must be done very thoroughly as it could also be
due to loss of balance in the differential torque converter clutch, etc.
(4) Check kick−down operation.
While running in the D position, 2nd, 3rd and O/D gears, check to see that the possible kick−down
vehicle speed limits for 2 → 1, 3 → 2 and O/D → 3 kick−downs conform to those indicated on
the automatic shift schedule (See page SS−49).
(5) Check abnormal shock and slip at kick−down.
(6) Check the lock−up mechanism.
Drive in D position, O/D gear, at a steady speed (lock−up ON).
Lightly depress the accelerator pedal and check that there is lock−up.
If there is a big jump in engine speed, there is no lock−up.
(b) 2 position test
Shift into the 2 position and fully depress the accelerator pedal and check the following points:
(1) Check up−shift operation.
Check to see that the 1 → 2 up−shift takes place and that the shift point conforms to the automatic
shift schedule (See page SS−49).

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DI−273
1996 TOYOTA T100 (RM449U)
Evaluation:
ProblemPossible cause
(a) Stall speed low in D and R positions
Engine output may be insufficient
Stator one−way clutch is operating properly
HINT: If more than 600 rpm below the specified value, the torque
converter could be faulty.
(b) Stall speed high in D position
Line pressure too low
forward clutch slipping
No.2 one−way clutch not operating properly
O/D one−way clutch not operating properly
(c) Stall speed high in R position
Line pressure too low
Direct clutch slipping
1st and reverse brake slipping
O/D one−way clutch not operating properly
(d) Stall speed high in D and R positions
Line pressure too low
Improper fluid level
O/D one−way clutch not operating properly
(b) Measure the time lag.
When the shift lever is shifted while the engine is idling, there will be a certain time lapse or lag before
the shock can be felt. This is used for checking the condition of the O/D direct clutch, forward clutch,
direct clutch, and 1st and reverse brake.
NOTICE:
Do the test at normal operating fluid temperature 50 − 80°C (122 − 176°F)
Be sure to allow 1 minute interval between tests.
Take 3 measurements and take the average value.
(1) Fully apply the parking brake.
(2) Start the engine and check idle speed.
Idle speed (In N position and air conditioner OFF):
3RZ−FE: 700 ± 50 rpm
5VZ−FE: 700 ± 50 rpm
(3) Shift the shift lever from N to D position. Using a stop watch, measure the time from when the
lever is shifted until the shock is felt.
In the same manner, measure the time lag for N → R.
Time lag:
N → D Less than 1.2 seconds
N → R Less than 1.5 seconds
Evaluation (If N → D time or N → R time lag is longer than specified):
ProblemPossible cause
N → D time lag is longer
Line pressure too low
Forward clutch worn
O/D one−way clutch not operating properly
N → R time lag is longer
Line pressure too low
Direct clutch worn
1st and reverse brake worn
O/D one−way clutch not operating properly

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DI−285
1996 TOYOTA T100 (RM449U)
Chapter 3: Off−Vehicle Repair Matrix Chart
(: A340E, A340F, A340H AUTOMATIC TRANSMISSION Repair Manual Pub. No. RM391U)
(: A340F, A343F AUTOMATIC TRANSMISSION Repair Manual Pub. No. RM479U)
SymptomSuspect AreaSee page
Vehicle does not move in any forward position and reverse posi-
tion
1. O/D one−way clutch (F0)
2. O/D direct clutch (C
0)
3. O/D planetary gear unit
4. Torque converter clutch



AT−38
Vehicle does not move in R position
1. Front and rear planetary gear unit
2. Direct clutch (C
2)
3. 1st and reverse brake (B
3)
4. O/D direct clutch (C
0)




No up−shift (1st → 2nd)1. 2nd brake (B2)
2. No. 1 one−way clutch (F
1)


No up−shift (2nd → 3rd)1. Direct clutch (C2)
No up−shift (3rd → O/D)1. O/D brake (B0)
No lock−up or No lock−up off1. Torque converter clutchAT−38
Harsh engagement (N → D)
1. Forward clutch (C1)
2. O/D one−way clutch (F
0)
3. No. 2 one−way clutch (F
2)



Harsh engagement (N → R)
1. Direct clutch (C2)
2. 1st and reverse brake (B
3)
3. O/D one−way clutch (F
0)



Harsh engagement (N → 2)
1. Forward clutch (C1)
2. O/D one−way clutch (F
0)
3. No. 2 one−way clutch (F
2)



Harsh engagement (N → L)
1. Forward clutch (C1)
2. 1st and reverse brake (B
3)
3. O/D one−way clutch (F
0)
4. No. 2 one−way clutch (F
2)




Harsh engagement (Lock−up)1. Torque converter clutchAT−38
Slip or shudder (Forward and reverse: After warm−up)
1. Torque converter clutch
2. O/D one−way clutch (F
0)
3. O/D direct clutch (C
0)
AT−38


Slip or shudder (Particular position: Just after engine starts)1. Torque converter clutchAT−38
Slip or shudder (R position)1. Direct clutch (C2)
2. 1st and reverse brake (B
3)


Slip or shudder (1st)1. Forward clutch (C1)
2. No. 2 one−way clutch (F
2)


Slip or shudder (2nd)
1. 2nd brake (B2)
2. 2nd coast brake (B
1)
3. No. 1 one−way clutch (F
1)



Slip or shudder (3rd)1. Direct clutch (C2)
Slip or shudder (O/D)1. O/D brake (B0)
No engine braking (1st ∼ 3rd: D position)1. 2nd brake (B2)
No engine braking (1st: L position)1. 1st and reverse brake (B3)
No engine braking (2nd: 2 position)1. 2nd coast brake (B1)
Poor acceleration (All position)1. Torque converter clutchAT−38
Poor acceleration (O/D)1. O/D direct clutch (C0)
2. O/D planetary gear unit

Engine stalls when starting off or stopping1. Torque converter clutchAT−38

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Drain
Line
Pressure
Q07640
DI−294
− DIAGNOSTICSAUTOMATIC TRANSMISSION
1996 TOYOTA T100 (RM449U)
DTC P0770 Shift Solenoid E Malfunction
(Shift Solenoid Valve SL)
SYSTEM DESCRIPTION
The ECM uses the signals from the Throttle position sensor,
mass air flow meter and crankshaft position sensor to monitor
the engagement condition of the lock−up clutch.
Then the ECM compares the engagement condition of the
lock−up clutch with the lock−up schedule in the ECM memory
to detect mechanical trouble of the shift solenoid valve SL,
valve body and torque converter clutch.
DTC No.DTC Detecting ConditionTrouble Area
P0770
Lock−up does not occur when driving in the lock−up range
(normal driving at 80 km/h [50 mph]), or lock−up remains ON
in the lock−up OFF range
(2 trip detection logic)Shift solenoid valve SL is stuck open or closed
Valve body blocked up or stuck
Lock−up clutch
INSPECTION PROCEDURE
1 Check solenoid valve SL operation.
PREPARATION:
(a) Remove the oil pan.
(b) Remove the shift solenoid valve SL.
CHECK:
(a) Applying 490 kPa (5 kgf/cm2, 71 psi) of compressed air,
check that the solenoid valve does not leak air.
(b) When battery voltage is supplied to the shift solenoid
valve, check that the solenoid valve opens.
NG Replace solenoid valve SL.
OK
DI0VR−01

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DI−295
1996 TOYOTA T100 (RM449U)
2 Check valve body (See page DI−282).
NG Repair or replace valve body.
OK
Replace torque converter clutch
(See page AT−26, AT−33).

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AUTOMATIC TRANSMISSION SYSTEM AT-1
EXTENSION HOUSING OIL SEAL
(A340E) AT-3
SENSOR ROTOR (A340E) AT-4
SPEEDOMETER DRIVEN GEAR AT-8
VEHICLE SPEED SENSOR AT-10
PARK/NEUTRAL POSITION (PNP)
SWITCH AT-11
VALVE BODY ASSEMBLY AT-12
PARKING LOCK PAWL AT-17
THROTTLE CABLE AT-18
SHIFT LOCK SYSTEM AT-19
AUTOMATIC TRANSMISSION UNIT
(A340E) AT-26
AUTOMATIC TRANSMISSION UNIT
(A340F) AT-33
TORQUE CONVERTER CLUTCH AND
DRIVE PLATE AT-38

Downloaded from www.Manualslib.com manuals search engine AT0ZK−01
AT6684
Q05731
200 mm
(7.87 in.)
0.8 − 1.5 mm (0.031 − 0.59 in) AT−18
− AUTOMATIC TRANSMISSIONTHROTTLE CABLE
1359 Author: Date:
1996 TOYOTA T100 (RM449U)
THROTTLE CABLE
ON−VEHICLE REPAIR
1. DISCONNECT THROTTLE CABLE
(a) Disconnect the cable from the throttle linkage.
(b) Disconnect the cable from the cable clamps in the engine
compartment.
(c) Remove the bolt and disconnect the cable clamp from the
torque converter clutch housing.
2. REMOVE VALVE BODY (See page AT−12)
3. REMOVE THROTTLE CABLE
Remove the retaining bolt and pull out the throttle cable.
4. INSTALL THROTTLE CABLE
(a) Make sure to push it in all the way.
(b) Install the bolt.
5. INSTALL VALVE BODY (See page AT−12)
6. IF THROTTLE CABLE IS NEW, STAKE STOPPER ON
INNER CABLE
HINT:
New cable does not have a staked cable stopper.
(a) Bend the cable so there is a radius of about 200 mm (7.87
in.).
(b) Pull the inner cable lightly until slight resistance is felt, and
hold it there.
(c) Stake the stopper, 0.8 − 1.5 mm (0.031 − 0.059 in.) from
the end of outer cable.
7. CONNECT THROTTLE CABLE
(a) Install the bolt and connect the cable clamp to the torque
converter clutch housing.
(b) Connect the cable to the cable clamps in the engine
compartment.
(c) Connect the cable to the throttle linkage.
8. ADJUST THROTTLE CABLE (See page DI−265)