Tài liệu sửa chữa hộp số tự động A650E

Tài liệu sửa chữa hộp số tự động A650E: 1. Install transmision case on overhaul atachment 2.Install Rear Planetary ring gear 3. Install output shaft with center and Rear Planetary gear 4.Install front Planetary gear 5.Install Muntiple disc Brake and No 1 one way cluntch....

D01250

Shift Solenoid Valve SLU

Shift Solenoid Valve SLN

Shift Solenoid Valve No 3

Shift Solenoid Valve No 1

Shift SolenoidValve No 2

Shift SolenoidValve No 4

Spring Plate

DetentSpring

Manual Valve

Pressure ReliefValve Spring Seat

6.4 (65, 56 in.·lbf)

No 1 Lock Plate

No 2 Lock Plate

SpringBall

Lower No 2 Valve Body

Strainer

Plate Orifice ControlThermal Valve

Lower No 1 Valve BodyCheck Valve

Upper Valve Body

PlugC-1 Accumulator Valve

Solenoid Modulator Valve

Check Valve

RetainerRetainer PlugRetainer

Lock-up Relay Valve

C-0 Exhaust Valve

4-5 Shift ValveCoast Brake Control Valve

Retainer

B-2 Release Control Valve

Primary Regulator Valve

Accumulator Control Valve

C-0 Control Relay Valve

Lock-up Control ValveSleeve

RetainerPlunger

D01257

Retainer

PlugSpring

Reverse Control Valve

AT-120

-AUTOMATIC TRANSMISSION LOWER NO.2 VALVE BODY

COMPONENTS

D09414

Adjusting Bolt

Park/NeutralPosition SwitchTransmissionWire

TransmissionCase

Parking Lock Pawl

Parking Lock Pawl Shaft

C2 Accumulator Piston

B0 Accumulator PistonValve Body

SpringCheck Ball Body

9.8 (100, 7)

Oil StrainerMagnet

Manual Valve Lever Shaft

Parking Lock Rod

Manual Valve Lever

7.4 (75, 65 in.·lbf)

Elbow

29 (300, 22)

Vehicle SpeedSensorLock Washer

7.4 (75, 65 in.·lbf)

SpringSnap Ring

O/D Direct Clutch

O/D Brake Pack

Bearing & Race Thrust Washer

21 (215, 16)

O/D PlanetaryRing Gear

Thrust Washer

Forward Clutch

3rd CoastBrake Band

Bearing

E-Ring Pin Assembled

Bearing & Race

Race

Forward ClutchHub

Race

2nd Brake Pack

Front Planetary Gear

Front & CenterPlanetary Sun Gear

Rear PlanetaryRing Gear

3rd Coast BrakePiston

3rd CoastBrake Cover

Brake DrumGasket

Output Shaftwith Center & RearPlanetary Gear

No 2 One-wayClutch

Multiple DiscBrakeSnap Ring

Sun GearInput Drum

ThrustWasherSnap Ring

D01280

Oil Pump Body

Oil Pump Drive Gear

D01414

O/D Direct Clutch Drum

O/D Direct Clutch Piston

O/D Planetary Gear

Outer Race

Bearing

O/D PlanetaryRing Gear

RaceThrust Washer

One-way ClutchInner Race

Ring Gear Flange

FlangeSnap Ring

2nd Brake Piston

Washer

Front Planetary Gear

Front & Center PlanetarySun Gear

Non-reusable part

Snap Ring

O-Ring

O-RingWasher

AT-78

-AUTOMATIC TRANSMISSION MULTIPLE DISC BRAKE

MULTIPLE DISC BRAKE

COMPONENTS

D01473

Front PlanetaryRing Gear

Snap Ring

Center Planetary Gear

Center PlanetaryRing Gear

Rear PlanetaryRing Gear Flange

Piston Return Spring

No 2 Brake Piston

compres-sion spring.

oil passage and be sure that the O/D brake piston movessmoothly

O/D SUPPORT

re-turn spring with a press

pas-sage to remove the O/D brake piston

(d)

(e)(g)

(h)

D01251

Oil CoolerReturn PipeClamp

-AUTOMATIC TRANSMISSION VALVE BODY

AT-105

DISASSEMBLY

Remove the bolt, detent spring and spring plate

SLN

SLU, SLT

and ball

2, No 3 and No 4

cooler return pipe and clamp So remove them all er

-AUTOMATIC TRANSMISSION VALVE BODY

plate

Remove the nut, washer and control shaft lever.

-AUTOMATIC TRANSMISSION COMPONENT PARTS

HINT:

If necessary, tap the extension housing with a plastic hammer

and oil pan, cut off applied sealer.

NOTICE:

Be careful not to damage the oil pan flange.

Remove the magnets and use them to collect steel particles.Carefully lock at the foreign matter and particles in the pan and

on the magnets to anticipate the type of wear you will find in thetransmission

wear

body

-AUTOMATIC TRANSMISSION COMPONENT PARTS

valves

Remove the check ball body and spring

NOTICE:

Take care as the B 0 and C 0 accumulator piston may jump out.

ac-cumulator piston and spring.

NOTICE:

Take care as the C 0 accumulator piston may jump out.

ac-cumulator piston and spring

HINT:

top part is removed, after removing the spring reapply pressed air to remove the bottom part

le-ver

then remove the lock pawl and spring

-AUTOMATIC TRANSMISSION COMPONENT PARTS

remove it from the shaft

HINT:

Slowly drive out the spring pin so it does not fall into the mission case

remove the manual valve lever

transmis-sion case

DI-RECT CLUTCH

from the transmission case

transmis-sion case

gear

-AUTOMATIC TRANSMISSION COMPONENT PARTS

Piston stroke: 1.32 - 1.62 mm (0.052 - 0.064 in.)

If the stroke is non-standard, inspect the discs

HINT:

Flange, 3 plates and 3 discs

from the case

from the O/D support.

BRAKE

brake piston rod, as shown in the illustration

Piston rod stroke: 2.0 - 3.0 mm (0.079 - 0.118 in.)

If the stroke is non-standard, inspect the brake band

-AUTOMATIC TRANSMISSION COMPONENT PARTS

AS-SEMBLY AND SPRING

coast brake cover, piston and spring

case

& RaceRace

Bearing

-AUTOMATIC TRANSMISSION COMPONENT PARTS

AT-15

and race from the forward clutch

HINT:

Apply the grease to the E-ring and pin before the work so thatthe ring does not fly out

INPUT DRUM

drum

and sun gear input drum, from forward clutch hub

-AUTOMATIC TRANSMISSION COMPONENT PARTS

BRAKE AND FRONT PLANETARY GEAR

PLANETARY GEAR

from the case

from the case

-AUTOMATIC TRANSMISSION COMPONENT PARTS

cen-ter & rear planetary gear

the rear planetary ring gear

Place the oil pump body on the torque converter clutch.

Remove the 2 oil seal rings

from the oil pump body

clutch

Push the driven gear to one side of the body

Using a feeler gauge, measure the clearance

Standard body clearance:

0.07 - 0.15 mm (0.0028 - 0.0059 in.) Maximum body clearance: 0.3 mm (0.012 in.)

If the body clearance is greater than the maximum, replace thedrive gear, driven gear or pump body

Using a feeler gauge, measure the clearance between the

driv-en gear teeth and the crescdriv-ent-shaped part of the pump body

Standard tip clearance:

0.11 - 0.14 mm (0.0043 - 0.0055 in.) Maximum tip clearance: 0.3 mm (0.012 in.)

If the tip clearance is greater than the maximum, replace thedrive gear, driven gear or pump body

-AUTOMATIC TRANSMISSION OIL PUMP

Using a steel straight edge and feeler gauge, measure the sideclearance of both gears

Standard side clearance:

0.02 - 0.04 mm (0.0008 - 0.0016 in.) Maximum side clearance: 0.1 mm (0.004 in.)

If the side clearance is greater than the maximum, replace thedrive gear, driven gear or pump body

Using SST, remove the oil seal

Hold the O/D direct clutch drum and turn the input shaft.The input shaft turns freely clockwise and locks counterclock-wise.

O/D PLANETARY GEAR

then place the O/D direct clutch assembly onto the oilpump

clutch piston stroke while applying and releasing

Piston stroke: 0.85 - 1.10 mm (0.033 - 0.043 in.)

If the stroke is non-standard, inspect the discs

direct clutch drum.

spring with a press

-AUTOMATIC TRANSMISSION OVERDRIVE DIRECT CLUTCH

then place the O/D direct clutch onto the oil pump

to remove the O/D direct clutch piston

HINT:

If the piston is at an angle and cannot be removed, press down

on the side jutting out and again apply compressed air, or elsewind vinyl tape around the piston end and remove it with needlenose pliers

washer

One-way

Clutch

InnerRace

Outer Race

InnerRace

-AUTOMATIC TRANSMISSION OVERDRIVE DIRECT CLUTCH

AT-59

Remove the 2 inner races and one-way clutch to the outer race

piston stroke while applying and releasing compressed

Piston stroke: 0.40 - 0.70 mm (0.016 - 0.028 in.)

If the clearance is non-standard inspect the discs

clutch drum

PistonReturnSpring

-AUTOMATIC TRANSMISSION DIRECT CLUTCH

re-move the direct clutch piston

HINT:

Make sure the direct clutch piston squares in the drum beforeapplying compressed air

piston

from touching the work stand, and place the O/D support

on them

Using SST and a dial indicator, measure forward clutch pistonstroke while applying and releasing compressed air (186 kPa,

Piston stroke: 0.60 - 0.90 mm (0.024 - 0.035 in.)

If the clearance is non-standard, inspect the discs

for-ward clutch drum

spring with a press

-AUTOMATIC TRANSMISSION FORWARD CLUTCH

sup-port to remove the forward clutch piston

Using a small screwdriver, remove the 2 O-rings

CLUTCH

Using SST and a dial indicator, measure the 3rd brake pistonstroke while applying and releasing compressed air (392 kPa,

If the stroke is non-standard, inspect the disc

Piston stroke: 0.56 - 0.86 mm (0.022 - 0.036 in.) NOTICE:

Do not applying compressed air into the 2nd brake hole.

drum

spring with a press

Retainer

PistonReturnSpring

2nd BrakePiston

AT-80

-AUTOMATIC TRANSMISSION MULTIPLE DISC BRAKE

passage to remove the 3rd brake piston

pis-tons

front planetary ring gear.

from center planetary ring gear

inter-mediate shaft

-AUTOMATIC TRANSMISSION REAR PLANETARY GEAR

DISASSEMBLY

planetary ring gear

Pack clearance: 0.5 - 0.8 mm (0.021 - 0.031 in.)

spring

re-move No 2 brake piston

Using a plastic hammer, remove the dust deflector.

Using a screwdriver, remove the oil seal

IN-6

-INTRODUCTION TERMS

GLOSSARY OF SAE AND LEXUS TERMS

This glossary lists all SAE-J1930 terms and abbreviations used in this manual in compliance with SAE ommendations, as well as their LEXUS equivalents

rec-SAE

LEXUS TERMS ( ) ABBREVIATIONS

1: Check Connector 2: Total Diagnosis Comunication Link (TDCL) 3: OBD II Diagnostic Connector

EEPROM Electrically Erasable Programmable Read Only Memory

Electrically Erasable Programmable Read Only Memory (EEPROM),

Erasable Programmable Read Only Memory (EPROM)

EPROM Erasable Programmable Read Only Memory Programmable Read Only Memory (PROM)

-INTRODUCTION TERMS

IN-7

Intake Vacuum

Electric Bleed Air Control Valve (EBCV) Mixture Control Valve (MCV)

Electric Air Control Valve (EACV)

Diesel Particulate Trap (DPT)

SFI Sequential Multiport Fuel Injection Electronic Fuel Injection (EFI), Sequential Injection

Central Fuel Injection (Ci)

-INTRODUCTION TERMS

Thermostatic Vacuum Switching Valve (TVSV)

TWC Three-W ay Catalytic Converter

Three-W ay Catalytic (TWC) Manifold Converter

CCROTWC+OC Three-W ay + Oxidation Catalytic Converter CCR + CCo

Hexagon Nut Cold Forging Nut Cutting Processed Nut

Normal Recess Bolt Deep Recess Bolt Stud Bolt Weld Bolt

D01280

Oil Pump Body

Oil Pump Drive Gear

An INDEX is provided on the first page of each section to guide you to the item to be repaired To assist you

in finding your way through the manual, the Section Title and major heading are given at the top of everypage

what to do and where

21 CHECK PISTON STROKE OF OVERDRIVE BRAKE

(a) Place SST and a dial indicator onto the overdrive brakepiston as shown in the illustration

Task heading : what to do

SST 09350-30020 (09350-06120)

Set part No Component part No

Detailed text : how to do task(b) Measure the stroke applying and releasing the compressed

Piston stroke: 1.40
1.70 mm (0.0551
0.0669 in.)

-INTRODUCTION HOW TO USE THIS MANUAL

The procedures are presented in a step-by-step format:

and warnings

Example:

This format provides the experienced technician with a FAST TRACK to the information needed The uppercase task heading can be read at a glance when necessary, and the text below it provides detailed informa-tion Important specifications and warnings always stand out in bold type

people

being repaired

help you perform the repair efficiently

INSPECT BRAKE BAND

If the lining of the brake band is peeling off or discolored, or even

if a part of the printed numbers are defaced, replace the brakeband

HINT:

Before assembling the new band, soak it in ATF for at least 15minutes

Check to see if the sliding surface of the disc, plate and flangeare worn or burnt If necessary, replace them.

HINT:

if a part of the printed numbers is defaced, replace alldiscs

least 15 minutes

Measure the free length of the spring together with the springseat

Standard free length: 17.82 mm (0.702 in.)

Using a caliper gauge, measure the inside diameter of the oilpump body bushing.

Maximum inside diameter: 38.19 mm (1.5035 in.)

If the inside diameter is greater than the maximum, replace theoil pump body

Using a caliper gauge, measure the inside diameter of the tor shaft bushing

sta-Maximum inside diameter:

Front side: 21.58 mm (0.8496 in.) Rear side: 27.08 mm (1.0661 in.)

If the inside diameter is grater than the maximum, replace thestator shaft

Check to see if the sliding surface of the disc, plate and flangeare worn or burnt If necessary, replace them.

HINT:

if a part of the printed numbers is defaced, replace alldiscs

least 15 minutes

low-pres-sure compressed air

Measure the free length of the spring together with the springseat

Standard free length: 15.8 mm (0.622 in.)

Using a dial indicator, measure the inside diameter of the clutchdrum bushings

Maximum inside diameter: 27.11 mm (1.0673 in.)

If the inside diameter is greater than the maximum, replace theclutch drum

Using a dial indicator, measure the inside diameter of the tary gear bushing.

plane-Maximum inside diameter: 11.27 mm (0.444 in.)

If the inside diameter is greater than the maximum, replace theplanetary gear

Measure the free length of the spring together with the springseat.

Standard free length: 23.25 mm (0.915 in.)

low-pres-sure compressed air

Check to see if the sliding surface of the disc, plate and flangeare worn or burnt If necessary, replace them

HINT:

if a part of the printed numbers is defaced, replace alldiscs

least 15 minutes

Using a deal indicator, measure the inside diameter of theclutch drum bushing

Maximum inside diameter: 53.97 mm (2.1248 in.)

If the inside diameter is greater than the maximum, replace theclutch drum

Check to see if the sliding surface of the disc, plate and flangeare worn or burnt If necessary, replace them.

HINT:

if a part of th printed numbers is defaced, replace all discs

least 15 minutes

low-pres-sure compressed air

Using a dial indicator, measure the inside diameter of the ward clutch drum bushing

for-Maximum inside diameter: 20.08 mm (0.790 in.)

If the inside diameter is greater than the maximum, replace theforward clutch drum

Check to see if the sliding surface of the disc, plate and flangeare worn or burnt If necessary, replace them.

HINT:

if a part of the printed numbers is defaced, replace alldiscs

least 15 minutes

Measure the free length of the spring together with the springseat

Standard free length: 36.8 mm (1.449 in.)

Hold the front & center planetary sun gear and turn the hub Thehub must be able to turn freely clockwise and locks counter-clockwise

AT-82

-AUTOMATIC TRANSMISSION MULTIPLE DISC BRAKE

BUSHING

Using a dial indicator, measure the inside diameter of the tary sun gear bushing

plane-Maximum inside diameter: 24.79 mm (0.976 in.)

If the inside diameter is greater then the maximum, replace theplanetary sun gear

Using a dial indicator, measure the inside diameter of the tary gear bushing

plane-Maximum inside diameter: 41.31 mm (1.626 in.)

If the inside diameter is greater than the maximum, replace theplanetary gear

Using a dial indicator, measure the inside diameter of the rearplanetary ring gear bushing.

Maximum inside diameter: 38.56 mm (1.518 in.)

If the inside diameter is greater than the maximum, replace therear planetary ring gear

Using a dial indicator, measure the inside diameter of the outputshaft bushing

Maximum inside diameter: 20.08 mm (0.791 in.)

If the inside diameter is greater than the maximum, replace theoutput shaft

Check to see if the sliding surface of the disc, plate and flangeare worn or burnt If necessary, replace them.

HINT:

if a part of the printed numbers is defaced, replace alldiscs

least 15 minutes

Measure the free length of the spring together with the springseat

Standard free length: 20.0 mm (0.787 in.)