Usage:
Start By:
a. remove drive shaft (front)
b. remove torque converter charging, scavenge and brake retraction pump
1. Disconnect wire harness connector (1) from the lockup clutch valve. Remove bolt (5), and move the wire harness away from the torque converter.
2. Disconnect hoses (2), and (3) from the rear of the torque converter.
3. Disconnect hose (6) from the filter group.
4. Remove the four bolts and guard assembly (7) from the transmission.
5. Disconnect hose (4) from the torque converter inlet relief valve.
6. Put identification marks on three wires (8), and disconnect the wires from the switches.
7. Disconnect hose (9) from the torque converter outlet relief valve.
8. Disconnect two hoses (10) from the torque converter.
9. Remove bolt (12), and move the clip and hose away from the torque converter.
10. Disconnect hose (11) from the air compressor.
11. Disconnect hose (13) from the torque converter.
12. Fasten a hoist and tool (A) to torque converter (14) as shown.
13. Remove the bolt and lock that hold sleeve (16) in place, and move the sleeve into the torque converter housing.
14. Remove bolts (15) that hold the torque converter to the flywheel housing, and lower the torque converter to the floor with the hoist and tool (A). The weight of the torque converter is 318 kg (700 lb).
15. Remove sleeve (16) from torque converter (14), and remove the O-ring seals from the sleeve.
16. Remove O-ring seal (17) from the torque converter.
Install Torque Converter
1. Put O-ring seal (2) in position on torque converter (1). Put the O-ring seals on sleeve (3). Put clean oil on the O-ring seals, and install the sleeve in the torque converter housing.
Typical Example
2. Put torque converter (1) in position on the flywheel housing with a hoist and tool (A), and install the bolts that hold the torque converter to the flywheel housing.
3. Move sleeve (3) into the flywheel housing, and install lock (4) and the bolt that holds it.
4. Connect hose (5) to the torque converter.
Typical Example
5. Connect hose (6) to the air compressor.
6. Connect two hoses (7) to the torque converter.
7. Put the hose and clip (8) in position on the torque converter, and install the bolt.
8. Connect three wires (9) to the switches.
9. Connect hose (10) to the torque converter outlet relief valve.
10. Connect hose (14) to the torque converter inlet relief valve.
11. Put the wire harness and clip in position on the lockup clutch valve, and install bolt (15). Connect wire harness connector (11) to the lockup clutch valve.
12. Put guard (17) and the wire harness clip in position on the transmission, and install the four bolts.
13. Connect hose (13) to the torque converter.
14. Connect hose (12) to the lockup clutch valve.
15. Connect hose (16) to the filter group.
End By:
a. install torque converter charging, scavenge and brake retraction pump.
b. install drive shaft (front)
Disassemble Torque Converter
Start By:
a. remove torque converter
Typical Example
1. Remove bolt (3), plate (1), shims, O-ring seal and flange (2) from the torque converter.
2. Remove bolts (4) that hold the cover to the torque converter.
Typical Example
3. Fasten a hoist and tooling (A) to cover (6). Install three 3/8 " - 16 NC forcing screws (5) in the cover. Tighten the forcing screws evenly, and remove the cover from the torque converter. The weight of the cover is 125 kg (275 lb).
4. Remove bolts (7) and pilot (8) from housing (9).
5. Remove two bolts (10), plate (11) and washer (12) from the shaft.
6. Turn the torque converter over. The weight of the torque converter is 181 kg (400 lb).
7. Remove two O-ring seals (15) from the carrier. Remove bolts (14) and retainer (13). Remove the gasket from the retainer.
8. Remove lip-type seal (16) from retainer (14).
9. Remove shaft assembly (17) from the converter.
10. Put a support under carrier (19). Use a press to push the shaft out of bearing (18) and the carrier.
11. Remove retainer ring (21) that holds carrier (20) on the carrier assembly with tool (D). Remove the carrier from the converter assembly.
12. Remove retainer ring (22) that holds sleeve (23) and bearing (24) in carrier (20).
13. Use tooling (C) to remove sleeve (23) and bearing (24) from the carrier.
14. Use tool (D) to remove retainer ring (25) from carrier assembly (26). Remove bolts (27) and washers that fasten plate (28) and the impeller to housing (9).
15. Install two 3/8 " - 16 NC forged eyebolts, and fasten a hoist as shown. Use two 3/8 " - 16 NCforcing screws (29) to separate the impeller and the housing. Remove the plate and impeller from the housing. The weight of the impeller assembly is 29 kg (65 lb).
16. Use tooling (E) to remove bearing race (30) from the hub.
17. Use tooling (F) to remove carrier (31) from the hub.
18. Remove bolts (34) that hold hub (33), gear (32), plate (28) and the impeller together. Remove the gear and plate from the hub and impeller.
19. Remove O-ring seal (36) and impeller (35) from hub (33).
20. Remove race and retainer assembly (37) and the bearing from the stator assembly.
21. Use two persons to remove stator and carrier assembly (38) from the turbine and housing. The weight of the stator and carrier assembly is 28 kg (62 lb).
22. Remove plate (39) from the stator assembly.
23. Remove carrier assembly (26) from the stator assembly (38). Remove springs (40) and rollers (41) from the stator assembly.
24. Remove ring (42) from carrier (26). Remove bearing (43) from the carrier only if a replacement is needed. Removal can cause damage to the bearing.
25. Remove retaining ring (44) and plate (45) from the stator.
26. Remove retainer ring (46) from the stator. Heat the stator to a maximum temperature of 135°C (275°F) for approximately fifteen minutes. Push cam (47) out of the stator.
27. Remove bearing (48), race and retainer from turbine (49).
28. Turn the housing and turbine over, and set the housing on wood blocks. Use a hammer and soft punch (brass, aluminum) to push hub (50) and turbine assembly out of bearing race (51). Remove the race and bearing.
29. Remove bolts (52) and hub (53) from the turbine (49).
30. Remove ring (55) from the hub. Remove bearing race (54) from the hub only if a replacement is needed. Removal can cause damage to the bearing race.
31. Remove retainer ring (56) for housing (9). Remove plate (57). Remove the two clutch plates and discs from the housing.
32. Use two 3/8 " - 16 NC forged eyebolts to remove piston (58) from the housing.
33. Remove seals (59) from piston (58) and housing (9).
34. Remove bearing race (60) from housing (9) only if a replacement is needed. Removal can cause damage to the bearing race.
Assemble Torque Converter
1. Make sure all parts of the torque converter are clean and free of dirt and foreign material before it is assembled.
Typical Example
2. Check the clearance between the turbine and the stator. The difference between dimension (N), the turbine inner diameter and dimension (M), the stator outer diameter must be 0.71 to 0.91 mm (.028 to .036 in) with new parts. The maximum permissible clearance with worn parts is 1.37 mm (.054 in).
Typical Example
3. Check the clearance between the impeller and the stator. The difference between dimension (P), the inner diameter of the impeller, and dimension (Q), the outer diameter of the stator, must be 0.71 to 0.91 mm (.028 to .036 in) with new parts. The maximum permissible clearance with worn parts is 1.37 mm (.054 in).
4. Check the clearance between the stator and the turbine. The difference between dimension (R), the inner diameter of the turbine, and dimension (S), the outer diameter of the stator, must be 0.56 to 0.71 mm (.022 to .028 in) with new parts. The maximum permissible clearance with worn parts is 1.07 mm (.042 in).
5. If bearing race (1) has been removed, lower the temperature of the bearing race, and install in housing (2) until the race makes contact with the shoulder in bottom of the bearing race bore.
6. Install seals (4) on piston (3) and in housing (2).
7. Install piston (3) in the housing.
8. Put hub (5) in position in the housing. Install two discs (7) and two plates (6). Start with a disc.
9. Install plate (8) and retainer ring (9) that holds the plate in the housing. Remove hub (5) from the housing.
10. If bearing race (11) was removed, heat the race to a temperature of 135°C (275°F), and install it on the hub until the race makes contact with the shoulder on the hub. Install ring seal (10) on the hub.
11. Put hub (5) in position on turbine (13), and install the bolts. Tighten the bolts to a torque of 120 ± 15 N·m (90 ± 11 lb ft). Make sure ring (12) is in position in hub (5).
12. Install bearing (14) and turbine (13) in the housing. The bearing must be held in position in the housing when the turbine is installed.
13. Install race and retainer assembly (16) and bearing (15) on the hub. Be sure the notch in the race is in alignment with pin (17) on the hub.
14. Use a press and tooling (A) to install the bearing in carrier (18). The installed bearing must be 1.52 ± 0.51 mm (.06 ± .02 in) below the surface of the carrier.
15. Install ring seal (19) on the carrier.
NOTE: There is identification on the cam that shows "IMPELLER SIDE" of the cam.
16. Install retainer ring (20) in stator (21). Heat the stator to a maximum temperature of 135°C (275°F). Install cam (22) in the stator as shown with the "IMPELLER SIDE" down. Install the cam until it makes contact with ring (20).
17. Install plate (24) and ring (23) in the stator.
| NOTICE |
|---|
The springs must be installed with the maximum number of loops toward the outside (cam side). |
18. Turn the stator over, and install carrier (18) as shown. Install springs (26) and rollers (25) in the cam with the springs in the deeper part of each cam groove.
19. Install plate (27) on the stator and carrier assembly.
| NOTICE |
|---|
The stator must be held in position on the carrier when the assembly is installed. |
20. Install the stator and carrier assembly in the turbine.
21. Install bearing (29) and retainer and race assembly (28) on the stator.
22. Install two 1/2 " - 13 NC guide pins in hub (30). Install impeller (31) on the hub. Install O-ring seal (32) on the hub.
23. Install plate (34) and gear (33) on the hub. Remove the guide pins, and install the bolts that fasten the gear to the hub. Tighten the bolts to a torque of 120 ± 15 N·m (90 ± 11 lb ft).
24. Heat carrier (36) and race (35) to a temperature of 135°C (275°F). Install the carrier and race on the hub. When the carrier becomes cooler, install the ring seal on the carrier.
25. Install two 3/8 " - 16 NC guide pins in housing (2). Install two 3/8 " - 16 NC forged eyebolts in the impeller assembly, and install the impeller assembly on the housing. The weight of the impeller assembly is 29 kg (65 lb). Install the bolts that fasten the plate and impeller to the housing. Tighten the bolts to a torque of 50 ± 7 N·m (37 ± 5 lb ft).
26. Install retainer ring (37) with tool (B).
27. Lower the temperature of bearing (41) and sleeve (39). Install the bearing and sleeve in carrier (40). Install retainer ring (38) in the carrier.
28. Install carrier assembly (40) on carrier (18).
29. Use tool (B) to install retainer ring (42) that holds carrier (40) on carrier (18).
30. Use a press to install carrier (44) on shaft (43) until the carrier makes contact with the shoulder on the shaft.
31. Install two seal rings (45) on the carrier.
32. Install bearing (46) on the shaft.
33. Install the lip-type seal in retainer (47) with tooling (A). Install the seal with the seal lip toward the inside of the retainer. Put a thin layer of SAE 30 oil on the seal lip.
34. Put shaft assembly (43) in position in the converter. Install a new gasket (48) between the retainer and carrier. Put the retainer in position on the carrier, and install the bolts and lockwasher that hold the retainer on the carrier. Tighten the bolts to a torque of 50 ± 7 N·m (37 ± 5 lb ft).
35. Install two O-ring seals (49) on the carrier.
36. Turn the converter assembly over. Install bearing race (50) on hub (5) with a hammer and soft punch (brass or aluminum).
37. Put washer (52) in position on the shaft with the concave (curved) side down, and install plate (53) and two bolts (51). Tighten the bolts to a torque of 80 ± 10 N·m (60 ± 7 lb ft).
38. Install pilot (54) and bolts (55). Tighten the bolts to a torque of 50 ± 7 N·m (37 ± 5 lb ft).
Typical Example
39. Turn the torque converter over. The weight of the torque converter is 180 kg (400 lb).
40. Install two 1/2 " - 13 NC × 4" guide bolts (56) in the carrier. Fasten a hoist and tooling (C) to cover (57). Put the cover in position on the torque converter, and install the bolts that hold the cover to the torque converter. The weight of the cover is 125 kg (275 lb).
41. Put flange (59) in position on shaft (43). Measure the distance between the end of the shaft and shoulder (58) on flange (59).
42. Install O-ring seal (62) on the flange.
43. Install shims (61) that have a total thickness of 0.13 to 0.25 mm (.005 to .010 in) less than the dimension found in Step 41. Install retainer (60) and the bolt. Tighten the bolt to a torque of 240 ± 25 N·m (175 ± 18 lb ft).
End By:
a. install torque converter