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Home >> Toyota >> 1987 >> Corolla Sedan L4-1587cc 1.6L DOHC (4A-F) >> Repair and Diagnosis >> Transmission and Drivetrain >> Automatic Transmission/Transaxle >> Countershaft >> Service and Repair

Countershaft: Service and Repair




COMPONENTS

DISASSEMBLY OF COUNTER SHAFT




1. REMOVE BEARING




2. REMOVE UNDERDRIVE PLANETARY SUN GEAR FROM COUNTER SHAFT




3. REMOVE SNAP RING FROM SUN GEAR WITH SNAP RING PLIERS




4. REMOVE SNAP RING FROM COUNTER SHAFT ASSEMBLY




5. REMOVE UNDERDRIVE PLANETARY GEAR




6. REMOVE THRUST NEEDLE BEARING AND RACE




7. REMOVE DRIVE PINION WITH OUTPUT FLANGE, BEARING INNER RACE AND SPACER
a. Using SST and press, remove the drive pinion with output flange, bearing and inner race.

SST 09350-32013 (09351-32150) and 09555-55010

b. Remove the spacer.




8. REMOVE SNAP RING
9. REMOVE RING GEAR




10. REMOVE BEARING
Using SST and press, remove the bearing.

SST 09950-00020




11. REMOVE BEARING OUTER RACE WITH BRASS BAR AND HAMMER




12. REMOVE UNDER DRIVE ONE-WAY CLUTCH FROM CLUTCH DRUM
13. REMOVE THRUST WASHER




14. REMOVE SNAP RING




15. REMOVE FLANGE, DISCS AND PLATES




16. COMPRESS PISTON RETURN SPRING AND REMOVE SNAP RING
a. Place SST on the spring retainer and compress the springs with a press.

SST 09350-32013 (09351-32070)

b. Remove the snap ring.

17. REMOVE RETURN SPRING




18. BLOW OUT PISTON
Apply compressed air into the oil passage to remove the piston.

If the piston does not come out, use needle-nose pliers to remove it.

INSPECTION OF UNDERDRIVE UNIT




1. INSPECT UNDERDRIVE CLUTCH PISTON
a. Check that the check ball is free by shaking the piston.
b. Check that valve does not leak by applying low- pressure compressed air.




2. INSPECT DISC, PLATE AND FLANGE
Check that the sliding surface of disc is not worn or burnt. If the disc is worn or burnt, replace all discs.

Then check that the sliding surfaces of plate and flange are not worn or burnt.

If necessary, replace them.

ASSEMBLY OF COUNTER SHAFT




1. INSTALL NEW O-RINGS ON PISTON
Coat the O-rings with ATF.

2. INSTALL UNDERDRIVE CLUTCH PISTON IN CLUTCH DRUM
Be careful not to damage the O-rings.




3. PLACE RETURN SPRING ON CLUTCH PISTON




4. COMPRESS RETURN SPRING AND INSTALL SNAP RING IN GROOVE
a. Place SST on the spring retainer, and compress the spring with a press.

SST 09350-32013 (09351-32070)

b. Install the snap ring with a screwdriver.

Be sure the end gap of snap ring is not aligned with the spring retainer claw.




5. INSTALL PLATES, DISCS AND FLANGE

Install in order:
A240L/4A-C - Plate-disc-plate-disc-plate-disc-flange (flat end downward)
A240E/4A-GE - Plate-disc-plate-disc-plate-disc-plate-disc-flange (flat end downward)

6. INSTALL SNAP RING




7. CHECK PISTON STROKE OF UNDERDRIVE CLUTCH
If replacing the discs, plates or flange, check the piston stroke.

a. Install the underdrive clutch in the transaxle case.
b. Using a dial indicator (long type pick or SST), measure the underdrive clutch piston stroke applying and releasing the compressed air (4 - 8 kg/sq.cm, 57 - 114 psi or 392 - 785 kPa) as shown.

SST 09350-32013 (09351-32190)

Piston stroke:
A240L 1.50 - 1.86 mm (0.0591 -0.0732 in.)
A240E 1.47 - 1.89 mm (0.0579 - 0.0744 in.)




8. If the piston stroke is less than the limit, parts may be misassembled and reinstall them.

If the piston stroke nonstandard, select another flange.

NOTE: There are two different flange thickness.

Flange thickness:
2.04 mm (0.0803 in.)
2.40 mm (0.0945 in.)




9. INSTALL THRUST WASHER TO CLUTCH DRUM
10. INSTALL UNDERDRIVE ONE-WAY CLUTCH
Install the one-way clutch with the claw of retainer up.

11. CHECK OPERATION OF ONE-WAY CLUTCH
Hold the clutch drum and turn the one-way clutch. The one-way clutch should turn freely counterclockwise and lock clockwise.




12. INSTALL BEARING OUTER RACES
a. Using SST and press, press in the thick race to the flange side of the drive pinion with output flange.

SST 09350-32013 (09351-32090, 09351-32180)

b. Using SST and press, press the thin race into the other side.

SST 09350-32013 (09351-32090, 09351-321501 09351-32180)




13. INSTALL BEARING TO COUNTER SHAFT
Using SST and press, press in the bearing of the thick inner race side.

SST 09350-32013 (09351-32180)




14. INSTALL RING GEAR AND SNAP RING




15. INSTALL NEW SPACER AND DRIVE PINION WITH OUTPUT FLANGE




16. INSTALL ANOTHER BEARING TO COUNTER SHAFT
Using SST and press, press in the another bearing.

SST 09350-32013 (09351-32180)

CAUTION: Be sure there is some clearance between the output flange and bearing.




17. INSTALL BEARING INNER RACE
Using SST and press, press in the inner race.

SST 09350-32013 (09351-32180)

CAUTION: Be sure that there is some clearance.

18. INSTALL LOCK NUT
19. ADJUST PRELOAD OF COUNTER SHAFT




20. INSTALL RACE AND BEARING
Coat the race and bearing with petroleum jelly and install them.




21. INSTALL UNDERDRIVE PLANETARY GEAR
22. INSTALL SNAP RING




23. INSTALL THRUST BEARING TO COUNTER DRIVEN GEAR
Coat the thrust bearing with petroleum jelly and install it onto the counter driven gear.

ADJUSTMENT OF COUNTER SHAFT PRELOAD




1. TEMPORARILY INSTALL COUNTER DRIVEN GEAR
Using a press, press in the driven gear to the counter shaft.




2. INSTALL SST TO COUNTER DRIVEN GEAR
a. Install SST to the driven gear.
b. Secure the counter shaft in a vise.

SST 09350-32013 (09351-32031)




3. TIGHTEN NEW LOCK NUT WITH SST

SST 09350-32013 (09351-32170)

Torque (Reference):
1,800 - 2,200 kg.cm (130 - 159 ft.lbf, 177 - 216 N.m)




4. MEASURE STARTING TORQUE OF COUNTER SHAFT
a. Snug down the bearing by turning the counter shaft.
b. Using SST and spring tension gauge, measure the starting torque of the counter shaft.

SST 09350-32013 (09351-32170)

Torque:
1.2 - 2.0 kg (2.6 - 4.4 lb, 12 - 20 N) with tension gauge
6 - 10 kg.cm (5.2 - 8.7 in.lb, 0.6 - 1.0 N.m) with torque gauge (hexagon nut side)

NOTE: If the torque is exceeded, replace the spacer and retorque.
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