UNIT REPAIR (AW30–40LE) 7A4–1

TRANSMISSION
UNIT REPAIR (AW30–40LE)
CONTENTS

Major Components (1)................................... 7A4–3 Planetary Sun Gear and No.1 One-Way
Major Components (1) and Associated Clutch ......................................................... 7A4–73
parts ........................................................... 7A4–3 Disassembled View .................................... 7A4–73
Disassembly steps...................................... 7A4–3 Disassembly ............................................... 7A4–74
Components (1)............................................. 7A4–5 Inspection and Repair................................. 7A4–74
Reassembly ................................................ 7A4–5 Reassembly ................................................ 7A4–75
Major Components (2)................................... 7A4–7 Second Brake Assembly (B–2)...................... 7A4–77
Major Componets (2) and Associated Disassembled View .................................... 7A4–77
Parts........................................................... 7A4–7 Disassembly ............................................... 7A4–77
Disassembly ............................................... 7A4–8 Inspection and Repair................................. 7A4–78

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Reassembly ................................................ 7A4–11 Reassembly ................................................ 7A4–78
Major Components (3)................................... 7A4–16 Rear Planetary Gear Assembly and Output
Major Components (3) and Associated Shaft ........................................................... 7A4–81
Parts........................................................... 7A4–16 Disassembled View .................................... 7A4–81
Disassembly ............................................... 7A4–17 Disassembly ............................................... 7A4–82
Reassembly ................................................ 7A4–25 Reassembly ................................................ 7A4–84
Diaassembly, Inspection and Reassembly First and Reverse Brake (B–3) ...................... 7A4–87
of minor Components................................. 7A4–37 Disassembled View .................................... 7A4–87
Oil Pump ........................................................ 7A4–38 Disassembly ............................................... 7A4–88
Disassembly View ...................................... 7A4–38 Reassembly ................................................ 7A4–89
Disassembly ............................................... 7A4–38 Transmission Valve Body assembly .............. 7A4–92
Inspection and Repair................................. 7A4–39 Disassembled View .................................... 7A4–92
Reassembly ................................................ 7A4–41 Disassembly ............................................... 7A4–93
OD Planetary Gear and OD Direct Clutch Reassembly ................................................ 7A4–93
Assembly (C–0).......................................... 7A4–43 Lower Valve Body .......................................... 7A4–96
Disassembled View .................................... 7A4–43 Cross Section ............................................. 7A4–96
Disassembly ............................................... 7A4–44 Disassembly ............................................... 7A4–98
Inspection and Repair................................. 7A4–47 Inspection and Repair................................. 7A4–103
Reassembly ................................................ 7A4–48 Reassembly ................................................ 7A4–104
OD Support Assembly ................................... 7A4–53 Upper Valve Body .......................................... 7A4–109
Disassembled View .................................... 7A4–53 Cross Section ............................................. 7A4–109
Disassembly ............................................... 7A4–53 Disassembly ............................................... 7A4–111
Inspection and Repair................................. 7A4–54 Inspection and Repair................................. 7A4–115
Reassembly ................................................ 7A4–55 Reassembly ................................................ 7A4–116
Direct Clutch Assembly (C-2) ........................ 7A4–58 Transmission Case ........................................ 7A4–121
Disassembled View .................................... 7A4–58 Disassembled View .................................... 7A4–121
Disassembly ............................................... 7A4–59 Disassembly ............................................... 7A4–121
Inspection and Repair................................. 7A4–60 Reassembly ................................................ 7A4–122
Reassembly ................................................ 7A4–61 Torque Converter........................................... 7A4–124
Forward Clutch Asseembly (C-1)................... 7A4–64 Inspection and Repair................................. 7A4–124
Disassembled View .................................... 7A4–64 Adapter Housing (4 ´ 4)................................. 7A4–125
Disassembly ............................................... 7A4–65 Disassembled View .................................... 7A4–125
Inspection and Repair................................. 7A4–66 Disassembly ............................................... 7A4–125
Reassembly ................................................ 7A4–67 Reassembly ................................................ 7A4–125
Front Planetary Gear ..................................... 7A4–71 Extension Housing (4 ´ 2) ............................. 7A4–126
Disassembled View .................................... 7A4–71 Disassembled View .................................... 7A4–126
Disassembly ............................................... 7A4–71 Disassembly ............................................... 7A4–126
Inspection and Repair................................. 7A4–71 Reassembly ................................................ 7A4–126
Reassembly ................................................ 7A4–72 Main Data and Specifications ........................ 7A4–128
7A4–2 UNIT REPAIR (AW30–40LE)
Special Tools .............................................. 7A4–132

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 UNIT REPAIR (AW30–40LE) 7A4–3

Major Components (1)

Major Components (1) and Associated parts

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RTW37AMF000601

Legend (8) Output revolution sensor (4´4)

(1) Torque converter (9) Output revolution sensor (4´2)
(2) Select lever (10) Speedometer sensor, speedometer driven gear
(3) Neutral start switch (Mode switch) and plate (4´2)
(4) Elbow (11) Extension housing (4´2)
(5) Oil temperature sensor (12) Adapter housing (4´4)
(6) Breather hose (13) Transmission assembly
(7) Input revolution sensor
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Disassembly steps
1. Remove the torque converter.
2. Remove the select lever.
7A4–4 UNIT REPAIR (AW30–40LE)
3. Remove the neutral start switch (Mode switch). 13. Remove the transmission assembly.
• Unstake the lock washer. • Install special tool to the transmission unit.
• Remove the nut and bolt, and then remove the Holding fixture: J–37227
neutral start switch. Holding fixture base: J–3289–20
• Remove the lock washer.

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RUW37ASH003001

RTW37BSH000101

4. Remove the two elbows from transmission case.

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5. Remove the oil temperature sensor.

6. Remove the breather hose.
7. Remove the Input revolution sensor.
8. Remove the output revolution sensor (4´4).
9. Remove the output revolution sensor (4´2).
10. Remove the speedometer sensor, speedometer
driven gear and plate (4´2).
11. Remove the extension housing (4´2).
12. Remove the adapter housing (4´4).
 UNIT REPAIR (AW30–40LE) 7A4–5

Components (1)

Reassembly • Align the neutral standard line and the switch

groove and tighten the adjusting bolt.
1. Install a new gasket and the extension housing
Torque: 13N·m (113Ibin)
(4´2) to the transmission case.
• Bend the tabs of the lock washer.
Torque: 36N·m (27Ibft)
2. Install the speedometer driven gear, plate, and NOTE: Bend at least two of the lock washer tabs.
speedometer sensor (4´2).
Torque:
Plate bolt – 15 N·m (11 Ibft)
Speedometer sensor – 25 N·m (18Ibft)
3. Install the adapter housing (4´4).
• Remove any gasket material on the contacting
surfaces of the adapter housing and transmission
case.

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RUW17ASH013601

5. Install the oil temperature sensor to the transmission

case.
Torque: 15N·m (11Ibft)

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• Apply liquid gasket (TB1281–B or its equivalent)

(1) and install the apply gaskets (2) to the adapter
housing as shown in the figure.
• Install the adapter housing to the transmission
case.
Torque: 34N·m (25Ibft)
4. Install the neutral start switch.
• Using the transmission select lever, fully turn the
manual valve lever shaft back and return two
notches.
RUW37ASH004001
It is now in neutral.
• Insert the neutral start switch onto the manual
valve lever shaft and temporarily tighten the
adjusting bolt.
• Install the lock washer and nut.
Torque: 7N·m (61Ibin)
7A4–6 UNIT REPAIR (AW30–40LE)
6. Install the elbow.
• Coat new O-rings with ATF, install them to the two
elbows.
• Install the two elbows as shown in the figure.
Torque: 29N·m (3.0kg·m/22Ibft)

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RTW37BSH000601

7. Install the select lever.

8. Install the output revolution sensor (4´2).
9. Install the output revolution sensor (4´4).
10. Install the input revolution sensor.
11. Install the breather hose.
12. Install the torque converter.
Using calipers and a straightedge, measure the
distance from the installed surface of the
transmission housing to top of the torque converter
nut.
Correct distance: 13.5mm (0.53in)

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 UNIT REPAIR (AW30–40LE) 7A4–7

Major Components (2)

Major Componets (2) and Associated Parts

Legend (9) Accumulator piston (B–0)

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RTW37ALF000801

(1) Converter housing (10) Accumulator piston (C–0)

(2) Oil pan (11) Second brake drum gasket
(3) Oil strainer assembly (12) Solenoid wiring
(4) Valve body (13) Snap ring, rotor, key (4´4)
(5) Check valve, spring (14) Snap ring, speedometer sensor drive gear, ball
(6) Spring (4´2)
(7) Accumulator piston (B–2) (15) Spacer, rotor, key, snap ring (4´2)
(8) Accumulator piston (C–2)
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7A4–8 UNIT REPAIR (AW30–40LE)

Disassembly • Look carefully at the chips and particles in the oil

pan and on the magnet to anticipate what type of
1. Remove the six bolts and remove the converter wear you will find in the transmission:
housing. Steel (magnetic) ...... bearing, gear and clutch
plate wear
Brass (non-magnetic)... bushing wear

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240R200022

2. Remove the oil pan.

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NOTE: Do not turn over the transmission as this will
contaminate the valve body with foreign materials in the 4. Remove the oil strainer assembly.
bottom of the oil pan. Remove four bolts holding the oil strainer.
• Remove the nineteen bolts.
• Remove oil pan by lifting the transmission case.
Oil pan seal cutter: J–37228

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RUW37ASH002901

3. Examine particles in oil pan.

• Remove the magnet and use it to collect any
steel chips.
 UNIT REPAIR (AW30–40LE) 7A4–9
5. Remove the valve body. • Remove the twenty bolts from valve body.
• Disconnect the connectors from the solenoid S1
(1), S2 (2), lock-up solenoid (3) and pressure
control solenoid (4).

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6. Remove the check valve and spring.
7. Remove two springs from C–0 accumulator piston.
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7A4–10 UNIT REPAIR (AW30–40LE)
8. Remove the accumulator piston (B–2). 11. Remove the C–0 accumulator piston.
9. Remove the accumulator piston (C–2).
• Remove accumulator pistons and springs from
transmission case.

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12. Remove the second brake drum gasket.
13. Remove the solenoid wiring.
240RY00010 • Turn over transmission, remove the solenoid
10. Applying compressed air to the oil hole, remove the wiring stopper plate from the case.
B–0 accumulator piston and spring. • Pull the wiring out of the transmission case.
14. Remove the snap ring, rotor and key (4´4).
• Remove the snap ring from the output shaft.
• Remove the rotor and key.

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15. Remove the snap ring, speedometer sensor drive

gear and ball (4´2).
• Remove the snap ring from the output shaft.
• Remove the speedometer sensor drive gear, and
ball.
 UNIT REPAIR (AW30–40LE) 7A4–11
16. Remove the spacer, rotor, key and snap ring (4´2). 3. Install the spacer, ball, speedometer sensor drive
• Remove the spacer, rotor and key. gear and snap ring (4´2).
• Remove the snap ring from the output shaft. • Install the spacer, ball and speedometer sensor
drive gear.
• Install the snap ring to the output shaft.

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247L100001

Reassembly 247L100001

4. Install the key, rotor and snap ring (4´4).

1. Install the converter housing.
• Install the key and rotor.
Torque: • Install the snap ring to the output shaft.
M10 – 34N·m (25lbft)
M12 – 57N·m (42lbft)

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2. Install the snap ring, key and rotor (4´2).

• Install the snap ring to the output shaft.
• Install the key and rotor.
7A4–12 UNIT REPAIR (AW30–40LE)
5. Install the second brake drum gasket. 7. Install the accumulator pistons.
• Install a new second brake drum gasket to the • Coat the O–ring with ATF and install it to the
transmission case. piston.
Install the three springs and four accumulator
pistons to the bore as shown in th figure.

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6. Individual piston operation inspection.

Check for the sound of operation while injecting 240RY00027

compressed air into the oil hole indicated in the Piston Outer diameter Height
figure.
B–2 36.8 mm (1.449 in) 62.5 mm (2.461 in)
C–2 36.8 mm (1.449 in) 56.6 mm (2.228 in)
B–0 31.8 mm (1.252 in) 52.0 mm (2.047 in)
C–0 29.8 mm (1.173 in) 44.0 mm (1.732 in)
mm (in)
Spring Free length Outer Color
diameter
B–2 74.6 (2.93) 19.7 (0.78) BROWN
C–2 68.5 (2.7) 20.2 (0.80) BLUE
(Outer)
C–2 (Inner) 42.1 (1.658) 14.7 (0.579) PINK
B–0 63.6 (2.504) 16.0 (0.630) RED
C–0 74.6 (2.937) 20.9 (0.823) ORANGE
(Outer)
C–0 (Inner) 46.0 (1.811) 14.0 (0.551) YELLOW
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Legend
(1) OD direct clutch
(2) Direct clutch
(3) Forward clutch
(4) OD brake
(5) Second coast brake
(6) Second brake
(7) First and reverse brake
(A) C–0 Accumulator piston hole
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NOTE: When inspecting the direct clutch, check with

the C–0 accumulator piston hole closed. If there is no
noise, disassemble and check the condition of the parts.
 UNIT REPAIR (AW30–40LE) 7A4–13
9. Install the valve body.
• Align the groove of the manual valve to the pin of
the lever.

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• Install the twenty bolts.

NOTE: Each bolt length (mm) is indicated in the figure.
Torque: 10N·m (87lbin)

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8. Install new check valve and spring.

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7A4–14 UNIT REPAIR (AW30–40LE)
10. Install the solenoid wiring. 11. Install a new oil strainer assembly with gaskets.
Coat a new O-ring with ATF, and install it to the
solenoid wiring.
Insert the solenoid wiring to the case and install the
stopper plate.
Connect the connectors to the solenoid S1 (1), S2
(2), lock-up solenoid (3), and pressure control
solenoid (4).

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• Install the oil strainer with the gaskets to the valve
body. Tighten the four bolts.
Torque: 10N·m (87lbin)

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 UNIT REPAIR (AW30–40LE) 7A4–15
12. Install the oil pan.
Install two magnets in oil pan.
Remove any gasket material and be careful not to
drop oil on the contacting surfaces of the
transmission case and oil pan.
Apply liquid gasket (TB1281 or its equivalent) to the
oil pan as shown in the figure.
NOTE: Install the oil pan as soon as the seal gasket is
applied.

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• Install and tighten the nineteen bolts.

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Torque: 7.4N·m (65lbin)

7A4–16 UNIT REPAIR (AW30–40LE)

Major Components (3)

Major Components (3) and Associated Parts

Legend (15) E-ring and pin

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248L100001

(1) Oil pump (16) Second coast brake band

(2) Race (17) Front planetary ring gear
(3) OD planetary gear and OD direct clutch (18) Bearing and race
(4) Race (19) Race
(5) OD planetary ring gear (20) Snap ring
(6) Snap ring (21) Front planetary gear
(7) Flange, plate and disc (B–0) (22) Drum and one-way clutch
(8) Bearing and race (23) Snap ring
(9) Snap ring (24) Flange, plate and disc (B–2)
(10) OD support (25) Snap ring
(11) Race (26) Rear planetary gear, second brake drum and
(12) Snap ring output shaft
(13) Second coast brake piston assembly (27) Bearing
(14) Direct clutch and forward clutch
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 UNIT REPAIR (AW30–40LE) 7A4–17

Disassembly 3. Remove the overdrive planetary gear and overdrive

direct clutch with thrust needle bearing from the
1. Remove seven bolts fixing the oil pump to the transmission case.
transmission case.
Remove the oil pump.

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252L100001

4. Remove the race from OD planetary gear.

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2. Remove race from oil pump.

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7A4–18 UNIT REPAIR (AW30–40LE)
5. Remove the overdrive planetary ring gear from the Available flange sizes
transmission case. 3.3 mm (0.130 in) 3.8 mm (0.150 in)
3.5 mm (0.138 in) 3.9 mm (0.154 in)
3.6 mm (0.142 in) 4.0 mm (0.158 in)
3.7 mm (0.146 in)

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252RY00002

6. Check piston stroke of overdrive brake

Place a dial indicator onto the overdrive brake
piston as shown in the figure.

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7. Remove the snap ring.

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Measure the stroke applying and releasing the

compressed air (390 – 780 kPa or 57 – 114 psi) as
shown in the figure. 246RY00001

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

If the values are nonstandard, select another flange.
 UNIT REPAIR (AW30–40LE) 7A4–19
8. Remove one flange, four plates and four discs (B– 10. Using snap ring pliers, remove the snap ring.
0).

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246RY00026 11. Remove the OD support.
9. Remove the thrust bearing and two races. • Remove two bolts fixing the overdrive support
assembly to the transmission case.

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7A4–20 UNIT REPAIR (AW30–40LE)
• Install two removed bolts to the OD support, and There are two piston rods.
pull out the OD support assembly.
Rod length 78.4 mm (3.09 in)
79.9 mm (3.15 in)

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12. Remove the race from OD support.

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13. Check piston stroke of second coast brake (B–1) 248RY00005

Place a mark on the second coast brake piston rod

as shown in the figure.
Using feeler gauge, measure the stroke applying
the compressed air (390 – 780 kPa or 57 – 114 psi)
as shown in the figure.
Piston stroke: 1.5 – 3.0mm (0.059 – 0.118in)
If the values are nonstandard, replace piston rod
and recheck piston stroke.
If piston stroke is nonstandard, replace brake band.
 UNIT REPAIR (AW30–40LE) 7A4–21
14. Using snap ring pliers, remove the snap ring. 16. Remove the direct clutch and forward clutch from
the transmission case.

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15. Applying compressed air to the oil hole, remove the 248RY00008

second coast brake piston assembly. 17. Remove the E-ring from the pin.
Remove the pin from the brake band.

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7A4–22 UNIT REPAIR (AW30–40LE)
18. Remove the second coast brake band from the 20. Remove the bearing and race.
transmission case.

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248RY00010 21. Remove the race.
19. Remove the front planetary ring gear from the
transmission case.

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22. Using snap ring pliers, remove the snap ring.

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 UNIT REPAIR (AW30–40LE) 7A4–23
NOTE: Hold the output shaft to prevent it from falling. 25. Using two screwdrivers, remove the snap ring.
The output shaft falls when the snap ring is removed.
23. Remove the front planetary gear from the
transmission case.

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26. Remove, five discs and six plates (B–2).

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24. Remove sun gear input drum and one-way clutch.

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7A4–24 UNIT REPAIR (AW30–40LE)
27. Check pack clearance of first and reverse brake (B– 29. Remove the rear planetary gear, second brake drum
3) and output shaft as an assembly.
Using a feeler gauge, measure the clearance
between the plate and second brake drum as shown
in the figure.
Clearance: 0.6 – 1.12mm (0.0236 – 0.0440in)
If the values are nonstandard, replace the discs.

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247R200001

30. Remove the assembled thrust bearing and race

from the transmission case.

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28. Using snap ring pliers, remove the snap ring.

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 UNIT REPAIR (AW30–40LE) 7A4–25

Reassembly • Align the splines of the transmission case and the

assembled rear planetary gear, second brake
1. Coat the assembled bearing and race with drum and output shaft, indicated by A in the
petroleum jelly and install it onto the transmission figure.
case.
Assembled bearing and race (Reference)
Bearing and race Diameter
Inside 39.38 mm (1.550 in)
Outside 58.15 mm (2.289 in)

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3. Using snap ring pliers, install the snap ring.

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2. Install the rear planetary gear, second brake drum

and output shaft.
• Align the teeth of the second brake drum,
flanges, discs and plates as shown in the figure.

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7A4–26 UNIT REPAIR (AW30–40LE)
4. Check pack clearance of first and reverse brake. 6. Install one-way clutch in the transmission case.
Using a thickness gauge, measure the clearance
between the plate and second brake drum as shown
in the figure.
Clearance: 0.60 – 1.12mm (0.0236 – 0.0440in)
If the values are nonstandard, check for an improper
installation.

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7. Install discs and plates (B–2).
Instal the 2.5mm (0.098in) thick plate with the
rounded edge side of the plate facing the disc.
Alternately install five discs and six plates (Disc first)

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5. Install second brake piston sleeve.

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 UNIT REPAIR (AW30–40LE) 7A4–27
8. Install the snap ring. 10. Install the front planetary gear and bearing to the
sun gear.
NOTE: Confirm the bearing and race is installed
correctly.
Bearing and race diameter (Reference)
Inside Outside
Bearing 35.6 mm (1.40 in) 47.7 mm (1.88 in)
Race 33.7 mm (1.33 in) 47.6 mm (1.87 in)

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9. While turning the sun gear input drum clockwise,
install it into the one-way clutch
NOTE: Confirm the thrust washer is installed correctly.

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With wooden blocks under the output shaft, stand

the transmission on the output shaft.

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7A4–28 UNIT REPAIR (AW30–40LE)
11. Using snap ring pliers, install the snap ring. 13. Insert the second coast brake band to the
transmission case.

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12. Coat the bearing race with petroleum jelly and install 248RY00010

it onto the front planetary gear. 14. Install the E-ring and pin.
Bearing race diameter (Reference) • Install the pin through the brake band.
Bearing race Diameter
Inside 34.3 mm (1.350 in)
Outside 47.8 mm (1.882 in)

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 UNIT REPAIR (AW30–40LE) 7A4–29
• Install the E-ring to the pin. 16. Coat the race with petroleum jelly and install it onto
the front planetary ring gear.
Race diameter (Reference)
Inside Outside
Race 26.8 mm (1.055 in) 47.0 mm (1.850 in)

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15. Coat the bearing and race with petroleum jelly and
install them onto the forward clutch.
Bearing and race diameter (Reference)
Inside Outside
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Bearing 26.0 mm (1.024 in) 46.7 mm (1.839 in)
Align the flukes of the discs in the forward clutch.
Race 26.0 mm (1.024 in) 48.9 mm (1.925 in)

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7A4–30 UNIT REPAIR (AW30–40LE)
17. Align the spline of the front planetary gear with the 19. Install the assembled direct clutch, forward clutch
flukes of the discs and install the front planetary and front planetary ring gear into the transmission
gear to the forward clutch. case.

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247RY00017 247RY00018

18. Coat the bearing and race with petroleum jelly and • Using vernier calipers, measure the distance
install them onto the ring gear. between the sun gear input drum and direct
Bearing and race diameter (Reference) clutch drum as shown in the figure.
Inside Outside Height: 2.5– 4.5 mm (0.098 – 0.177 in)
Bearing 35.15 mm (1.384 in) 53.65 mm (2.112 in)
If the values are nonstandard, check for an
Race 35.15 mm (1.384 in) 53.65 mm (2.112 in) improper installation.

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 UNIT REPAIR (AW30–40LE) 7A4–31
Coat the assembled bearing and race with 21. Coat two new oil seals with ATF and install them to
petroleum jelly and install it onto the forward the piston cover.
clutch. Install the spring, second coast brake piston
Assembled bearing and race diameter assembly and piston cover to the transmission
(Reference) case.
Inside Outside Using snap ring pliers, install the snap ring.
Bearing
33.7 mm (1.33 in) 47.8 mm (1.88 in)
and race

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248RY00027

22. Check piston stroke of second coast brake

Place a mark on the second coast brake piston rod
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as shown in the figure.
20. Assembly second coast brake piston assembly.
Coat the oil seal ring with ATF and install it to the
second coast brake piston.
Install the washer, spring and piston to the piston
rod. Install the E-ring.

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Using wire gauge, measure the stroke by applying

the compressed air (390 – 780 kPa or 57 – 114 psi)
as shown in the figure.
Piston stroke: 1.5 – 3.0mm (0.059 – 0.118in)
RUW37ASH004401

Legend
(1) Second coast brake piston
(2) Oil seal
(3) Piston rod
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7A4–32 UNIT REPAIR (AW30–40LE)
If the values are nonstandard, check for an improper 24. Aim the bolt and oil holes of the overdrive support
installation. toward the valve hole side, and align them with the
bolt hole of the transmission case and insert the
overdrive support.

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23. Coat the race with petroleum jelly and install it onto
the overdrive support assembly. 252RY00005

Race diameter (Reference) 25. Using snap ring pliers, install the snap ring as
Inside Outside shown in the figure.
Race 36.7 mm (1.44 in) 50.8 mm (2.00 in)

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 UNIT REPAIR (AW30–40LE) 7A4–33
• Install and tighten the two bolts. 27. Install the (flat ring) 4.0 mm (0.157 in) thick flange
with the rounded edge side of the flange facing the
Torque: 25N·m (19lbft)
disc.
Alternately install four discs and four plates. (Disc
first)

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252RY00004

26. Check end of output shaft.

Using a dial indicator, measure the end play of the
252RY00009
output shaft by hand.
28. Install the (stepped ring) flange with the flat side of
End play: 0.27 – 0.86 mm (0.0106 – 0.0339 in) the flange facing the disc.
Install the snap ring.
Snap ring (Reference)
Inside diameter 167.9 mm (6.61 in)

247RY00020

246RY00001
7A4–34 UNIT REPAIR (AW30–40LE)
29. Check piston stroke of overdrive brake. Remove the snap ring.
Place a dial indicator onto the overdrive brake
piston as shown in the figure.

246RY00001

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Remove one flange, four plates and four discs.
252RY00003

Measure the stroke by applying and releasing the

compressed air (390 – 780 kPa or 57 – 114 psi) as
shown in the figure.
Piston stroke: 1.40 – 1.70 mm (0.0551 – 0.0669 in)
If the values are nonstandard, check for an improper
installation.
Available flange size
3.3 mm (0.130 in) 3.8 mm (0.150 in)
3.5 mm (0.138 in) 3.9 mm (0.154 in)
3.6 mm (0.142 in) 4.0 mm (0.158 in)
3.7 mm (0.146 in)

246RY00026

244RY00001
 UNIT REPAIR (AW30–40LE) 7A4–35
30. Coat the bearing and races with petroleum jelly and 32. Coat the bearing and race with petroleum jelly and
install them onto the overdrive support. install them onto the planetary ring gear.
Bearing and races diameter (Reference) Bearing and race diameter (Reference)
Inside Outside Inside Outside
Race Bearing
37.2 mm (1.465 in) 58.8 mm (2.315 in) 24.2 mm (0.953 in) 47.8 mm (1.882 in)
(Front) and race
Bearing
and race 33.7 mm (1.327 in) 50.1 mm (1.972 in)
(Rear)

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252RY00011

Install the (flat ring) 4.0 mm (0.157 in) thick flange

with the rounded edge side of the flange facing the
disc.
252RY00010
Alternately install four discs and three plates. (Disc
31. Install the overdrive planetary ring gear.
first)
Install the (stepped ring) flange with the flat side of
the flange facing the disc.
Install the snap ring.
33. Coat the race with petroleum jelly and install it onto
the planetary gear.
Race diameter (Reference)
Inside Outside
Race 24.7 mm (0.972 in) 41.8 mm (1.646 in)

252RY00002

252RY00001
7A4–36 UNIT REPAIR (AW30–40LE)
34. Install the overdrive planetary gear and direct clutch. 36. Coat the race with petroleum jelly and install it onto
the oil pump.
Race diameter (Reference)
Inside Outside
Race 28.6 mm (1.126 in) 46.5 mm (1.831 in)

252L100001

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35. Coat the assembled bearing and race with
petroleum jelly and install it onto the direct clutch.
Bearing and race diameter (Reference)
Inside Outside
252RY00014
Bearing
28.9 mm (1.138 in) 50.2 mm (1.976 in) 37. Coat the O-ring with ATF and install it around the
and race
pump body.
Place the oil pump through the input shaft, and align
the bolt holes of the pump body with the
transmission case.
Hold the input shaft, and lightly press the oil pump
body to slide the oil seal rings on the stator shaft
through the direct clutch drum.
CAUTION:
Do not push on the oil pump strongly or the oil
seal ring will stick to the direct clutch drum.
Install the seven bolts.
Torque: 22 N·m (16 lbft)
38. Check input shaft rotation.
Make sure the input shaft rotates smoothly.

252L100018

241RY00003
 UNIT REPAIR (AW30–40LE) 7A4–37

Diaassembly, Inspection and

Reassembly of minor Components
NOTE: The instructions here are organized so that you
work on only one component group at a time.
This will help avoid confusion from similar-looking parts
of different subassemblies being on your workbench at
the same time.
The component groups are inspected and repaired from
the converter housing side.
As much as possible, complete the inspection, repair
and reassembly before proceeding to the next
component group. If a component group cannot be
reassembled because parts are being ordered, be sure
to keep all parts of that group in separate container
while proceeding with disassembly, inspection, repair
and reassembly of other component groups.
Recommended ATF type DEXRON III.

General Cleaning Notes:

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1. All disassembled parts should be washed clean and
any fluid passages and holes should be blown
through with compressed air.
2. When using compressed air to dry parts, always aim
away from yourself to prevent accidentally spraying
automatic transmission fluid in your face.
3. The recommended automatic transmission fluid
should be used for cleaning.

Parts Arrangement:
1. After cleaning, the parts should be arranged in
proper order to allow performing inspection, repairs,
and reassembly with efficiency.
2. When disassembling a valve body, be sure to keep
each valve together with the corresponding spring.
3. New brakes and clutches that are to be used for
replacement must be soaked in transmission fluid
for at least thirty minutes before assembly.

General Assembly:
1. All oil seal rings, clutch discs, clutch plates, rotating
parts, and sliding surfaces should be coated with
transmission fluid prior to reassembly.
2. All gaskets and rubber O-ring should be replaced.
3. Make sure that the ends of a snap ring are not
aligned with one of the cutouts and are installed in
the groove correctly.
4. If a worn bushing is to be replaced, the
subassembly containing that bushing must be
replaced.
5. Check thrust bearings and races for wear or
damage. Replace if necessary.
6. Use petroleum jelly or vaseline to keep parts in
place.
7A4–38 UNIT REPAIR (AW30–40LE)

Oil Pump

Disassembly View

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241R200003

Legend (4) Oil pump drive gear

(1) Oil seal ring (5) Oil pump driven gear
(2) O-ring (6) Oil pump body
(3) Stator shaft
E nd O FCallo ut

Disassembly
1. Use torque converter as work stand.
Remove 2 oil seal rings from stator shaft.

241RY00005
 UNIT REPAIR (AW30–40LE) 7A4–39
2. Remove the O-ring. 2. Check stator shaft bushing.
3. Remove the stator shaft. Using a dial indicator, measure the inside diameter
of the stator shaft bushing.
4. Remove the oil pump drive gear.
5. Remove the oil pump driven gear. Maximum inside diameter: Front side: 21.58mm
(0.8496in)
6. Remove the oil pump body.
Remove 13 bolts, and then remove the stator shaft Maximum inside diameter: Rear side: 27.08mm
from oil pump body. (1.0661in)
Then remove drive and driven gear.
If the inside diameter is greater than the maximum,
replace the stator shaft.

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241RY00006

241RY00008

Inspection and Repair 3. Check tip clearance of both gears.

Make necessary correction or parts replacement if wear, Measure between the gear teeth and the
damage or any abnormal conditions are found through cresent-shaped part of the pump body.
inspection. Standard tip clearance: 0.11 – 0.14mm (0.0043 –
1. Check oil pump body bushing. 0.0055in)
Using a dial indicator, measure the inside diameter Maximum tip clearance: 0.19mm (0.0075in)
of the oil pump body bushing.
If the tip clearance is greater than the maximum,
Maximum inside diameter: 38.19mm (1.5035in) replace the drive gear, driven gear or pump body.
If the inside diameter is greater than the maximum,
replace the oil pump body.

241RY00009

241RY00007
7A4–40 UNIT REPAIR (AW30–40LE)
4. Check body clearance of driven gear. 6. Check oil seal.
Push the driven gear to one side of the body. Check for wear, damage or cracks.
Use a feeler gauge, measure the clearance. If necessary, replace oil seal.
Pry off the oil seal with a screwdriver.
Standard body clearance: 0.07 – 0.15mm (0.0028
– 0.0059in)
Maximum body clearance: 0.2mm (0.0079in)
If the body clearance is greater than the maximum,
replace the drive gear, driven gear or pump body.

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241RY00012

Using special tool, install a new oil seal.

The oil seal end should be flush with the outer edge
of the pump body.
Oil seal installer : J–9617
Coat the oil seal lip with multipurpose grease.
241RY00010

5. Check side clearance of both gears.

Using a steel straightedge and a feeler gauge,
measure the side clearance of both gears.
Standard side clearance: 0.02 – 0.05mm (0.0008 –
0.0020in)
Maximum side clearance: 0.1mm (0.004in)
If the side clearance is greater than the maximum,
replace the drive gear, driven gear or pump body.

241RY00013

241RY00011
 UNIT REPAIR (AW30–40LE) 7A4–41

Reassembly 5. Install the oil seal ring.

• Coat the oil seal rings with ATF.
1. Place the oil pump body on the torque converter.
• Contract the oil seal rings as shown, and install
2. Coat the driven gear and drive gear with ATF. them onto the stator shaft.
3. Install the driven gear and drive gear.
NOTE: Do not spread the ring ends too much.

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241RY00015
4. Align the stator shaft with the bolt holes.
6. Coat a new O-ring with ATF and install it to the oil
Tighten the thirteen bolts.
pump body.
Torque: 10N·m (87Ibin) O-ring size (Reference)
Inside diameter 204.9mm (8.067in)
Thickness 3.5mm (0.138in)

241RY00006

241RY00016
7A4–42 UNIT REPAIR (AW30–40LE)
7. Check oil pump drive gear rotation.
Make sure the drive gear rotates smoothly when
installed to the torque converter.

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241RY00017
 UNIT REPAIR (AW30–40LE) 7A4–43

OD Planetary Gear and OD Direct Clutch Assembly (C–0)

Disassembled View

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RTW37AMF000701

Legend (10) Race and bearing asm

(1) OD direct clutch assembly (11) Snap ring
(2) OD planetary gear assembly (12) Ring gear flange
(3) Thrust bearing (13) OD planetary ring gear
(4) Snap ring (14) Race
(5) Flange, disk and plate (15) Snap ring
(6) Snap ring (16) Retaining plate
(7) Piston return spring (17) OD one-way clutch
(8) OD direct clutch piston (18) Thrust washer
(9) O-ring
E nd O FCallo ut
7A4–44 UNIT REPAIR (AW30–40LE)

Disassembly 4. Check piston stroke of OD direct clutch (C–0).

Place the oil pump onto the torque converter, and
1. Check operation of one-way clutch. then place the OD direct clutch assembly onto the
Hold the OD direct clutch drum and turn the input oil pump.
shaft.
The input shaft should turn freely clockwise and
should lock counterclockwise.

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252L100005

Use a dial indicator, measure the OD direct clutch

piston stroke applying and releasing the
RUW37ASH004501 compressed air (390 – 780 kPa or 57 – 114 psi) as
2. Remove OD direct clutch assembly from OD shown.
planetary gear assembly. Piston stroke: 1.85 – 2.15mm (0.0728 – 0.0846in)

252L100004
252L100016

3. Then remove thrust bearing with the race from OD

direct clutch drum.
 UNIT REPAIR (AW30–40LE) 7A4–45
5. Remove snap ring from clutch drum. • Remove the OD direct clutch piston.

252L100006 252L100008

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6. Remove flange, two discs and two plates. 10. Remove two O–rings from piston.
7. Place special tool on the spring retainer and 11. Remove bearing and race from OD planetary ring
compress the return spring. gear.
Using snap ring pliers, remove the snap ring.
Spring compressor : J–23327–1

RTW46BSH000301

252L100007

8. Remove piston return spring

9. Remove the OD direct clutch piston with O-ring.
• Place the oil pump onto the torque converter and
then place the OD direct clutch onto the oil pump.
• Holding the OD direct clutch piston by hand,
apply compressed air to the oil pump to remove
the OD direct clutch piston.
7A4–46 UNIT REPAIR (AW30–40LE)
12. Remove snap ring. 15. Remove snap ring, using screwdriver.

252RY00022 252RY00024

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13. Remove ring gear flange from OD planetary ring 16. Remove retaining plate from OD planetary gear.
gear.

252RY00025

252RY00023 17. Remove OD one-way clutch with outer race.

14. Remove the Race.

252RY00026
 UNIT REPAIR (AW30–40LE) 7A4–47
18. Remove the thrust washer. 3. Check OD direct clutch piston.
Check that the check ball is free by shaking the
piston. Check that the valve does not leak by
Inspection and Repair applying low-pressure compressed air.
1. Check discs.
Using a micrometer, measure the thickness of the
discs.
Minimum thickness: 2.04mm (0.0803in)
If the thickness is less than the minimum, replace
the disc.

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252RY00029

4. Check OD direct clutch drum bushings.

Using a dial indicator, measure the inside diameter
of the OD direct clutch drum bushings.
Maximum inside diameter: 27.11mm (1.0673in)
If the inside diameter is greater than the maximum,
252RY00027 replace the OD direct clutch drum.
2. Check piston return spring
Using calipers, measure the free length of the return
spring.
Standard length: 15.8mm (0.622in)

252L100009

252RY00028
7A4–48 UNIT REPAIR (AW30–40LE)
5. Check OD planetary gear bushing. 2. Install the one-way clutch into the outer race, with
Using a dial indicator, measure the inside diameter the flanged side of the one-way clutch facing
of replace the OD planetary gear bushing. upward.
Maximum inside diameter: 11.27mm (0.4437in)
If the inside diameter is greater than the maximum,
replace the OD planetary gear.

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252RY00033

3. Install OD one-way clutch with outer race to

overdrive planetary gear.

252RY00031

Reassembly
1. Install the thrust washer to the OD planetary gear,
facing the grooved side upward.

252RY00026

252RY00032
 UNIT REPAIR (AW30–40LE) 7A4–49
4. Install retaining plate, then install snap ring, using a 6. Install ring gear flange to OD planetary ring gear.
screwdriver.

252RY00023

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252RY00024 7. Install snap ring, using a screwdriver.
5. Coat the race with petroleum jelly and install it to the
planetary gear.
Race diameter (Reference)
Inside diameter 24.7mm (0.972in)
Outside diameter 41.8mm (1.646in)

252RY00022

252RY00034
7A4–50 UNIT REPAIR (AW30–40LE)
8. Install the race and bearing asm onto the OD 11. Install piston return spring.
planetary ring gear.
Race and bearing asm diameter (Reference)
Inside Outside
Bearing
24.2mm (0.953in) 47.8mm (1.882in)
and race

252L100012

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12. Place special tool on the spring retainer, and
compress the return spring.
Spring compressor : J–23327–1
Install the snap ring with snap ring pliers.
Be sure the end gap of the snap ring is not aligned
RTW37ASH001101
with the spring retainer claw.
9. Coat new O-rings with ATF and install them on the
OD direct clutch piston.
10. Being careful not to damage the O-rings, press in
the OD direct clutch piston into the clutch drum,
using both hands.

252L100007

252L100011
 UNIT REPAIR (AW30–40LE) 7A4–51
13. Install two plates and two discs then install the 15. Check piston stroke of OD direct clutch (C–0)
flange, with the flat side facing downward. Place the oil pump onto the torque converter, and
then place the OD direct clutch assembly onto the
oil pump.

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252L100013

14. Install snap ring.

252L100005

Using a dial indicator, measure the OD direct clutch

piston stroke by applying and releasing the
compressed air (390 – 780 kPa or 57 – 114 psi) as
shown.
Piston stroke: 1.85 – 2.15mm (0.0729 – 0.0847in)
If the piston stroke is not within specification,
replace the disc and recheck the piston stroke.
If the piston stroke is nonstandard, select another
flange.
Flange sizes
Flange thickness Flange thickness
3.8mm (0.150in) 3.4mm (0.134in)
3.7mm (0.146in) 3.3mm (0.130in)
3.6mm (0.142in) 3.2mm (0.126in)
3.5mm (0.138in) 3.1mm (0.122in)
252L100014

252L100016
7A4–52 UNIT REPAIR (AW30–40LE)
16. Coat the assembled bearing and race with 18. Check operation of one-way clutch
petroleum jelly and install it with the race side facing Hold the OD direct clutch drum and turn the input
downward. shaft.
Bearing and race (Reference) The input shaft should turn freely clockwise and
Inside diameter 28.9mm (1.138in) should lock counterclockwise.
Outside diameter 50.2mm (1.976in)

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RUW37ASH004501

Legend
252L100015 (1) Free
17. Align the flukes of discs in the direct clutch. (2) Lock
Install the OD direct clutch assembly onto the OD E nd OFCa llou t

planetary gear.

252L100004
 UNIT REPAIR (AW30–40LE) 7A4–53

OD Support Assembly

Disassembled View

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252R200003

Legend (5) Piston return spring

(1) Thrust bearing (6) OD brake piston
(2) Race (7) O-ring
(3) Thrust washer (plastic) (8) Oil seal ring
(4) Snap ring (9) OD support
E nd O FCallo ut

Disassembly
1. Check OD brake piston movement.
Place the OD support assembly onto the direct
clutch assembly.

252RY00042
7A4–54 UNIT REPAIR (AW30–40LE)
Apply compressed air into the oil passage as 7. Place the OD support onto the direct clutch
shown, and be sure that the OD brake piston moves assembly.
smoothly. Hold the OD brake piston so it is not slanted and
apply compressed air into the passage to remove
the OD brake piston.
Remove the OD brake piston.

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252RY00043

2. Remove the thrust bearing.

3. Remove the race.
252RY00045
4. Remove the thrust washer (plastic).
8. Remove the O-ring and oil seal rings from OD
5. Place special tool on the spring retainer, and support.
compress the return spring with a shop press.
Spring compressor : J–37233 Inspection and Repair
Remove the snap ring with a screwdriver.
Make necessary correction or parts replacement if wear,
damage or any abnormal conditions are found through
inspection.
1. Check piston return spring
Using calipers, measure the free length of the return
spring.
Standard length: 17.2mm (0.677in)

RUW37ASH003101

6. Romove the piston return spring.

252RY00046
 UNIT REPAIR (AW30–40LE) 7A4–55

Reassembly 4. Install piston return spring.

1. Coat the two oil seal rings with ATF.

Contract the oil seals as shown, and install them
onto the OD support.
NOTE: Do not spread the ring ends more than
necessary.

252RY00049

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5. Place special tool on the spring retainer, and
compress the return spring with a shop press.
Spring compressor : J–37233
Install the snap ring with a screwdriver.
Be sure the end gap of the snap ring is not aligned
252RY00047
with cutout portion of the OD support.
2. Coat two new O-rings with ATF and install them on
the OD brake piston.
3. Being careful not to damage the O-rings, press the
brake piston into the OD support, using both hands.

RUW37ASH003201

252RY00048
7A4–56 UNIT REPAIR (AW30–40LE)
6. Coat the thrust washer (plastic) with petroleum jelly 8. Turn over OD support.
and install it onto the OD support. Coat the two races with petroleum jelly, and install
them onto the OD support.
NOTE: Make sure that the lug fits into the hole on the
Race and bearing diameter (Reference)
OD support.
Inside Outside
Race (A) 37.2mm (1.465in) 58.8mm (2.315in)
Bearing and
33.7mm (1.327in) 50.1mm (1.972in)
race (B)

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252RY00051

7. Coat the race with petroleum jelly, and install it onto

the OD support.
Race diameter (Reference)
Inside diameter 36.7mm (1.44 in)
252RY00069
Outside diameter 50.85 mm (2.00 in)
9. Check OD brake piston movement.
Place the OD support assembly onto the direct
clutch assembly.

252RY00052

252RY00042
 UNIT REPAIR (AW30–40LE) 7A4–57
Apply compressed air into the oil passage as
shown, and be sure that the OD brake piston moves
smoothly.

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252RY00043
7A4–58 UNIT REPAIR (AW30–40LE)

Direct Clutch Assembly (C-2)

Disassembled View

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248R200001

Legend (5) Snap ring

(1) Clutch drum thrust washer (Plastic) (6) Piston return spring
(2) Snap ring (7) Direct clutch drum
(3) Flange (8) Direct clutch piston
(4) Plate and disc (9) O-ring
Five plates and five discs
E nd O FCallo ut
 UNIT REPAIR (AW30–40LE) 7A4–59

Disassembly Using a dial indicator, measure the direct clutch

piston stroke by applying and releasing compressed
Remove direct clutch drum assembly from forward air (390 – 780 kPa or 57 – 114 psi) as shown.
clutch assembly.
Pack clearance: 0.4 – 0.7 mm (0.016 – 0.028 in)

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248RY00028
RUW37ASH004901
1. Check piston stroke of direct clutch (C–2).
2. Remove the clutch drum thrust washer (Plastic)
Place the direct clutch assembly onto the OD
from the rear end of direct clutch.
support assembly.
3. Remove the snap ring from the direct clutch drum.
4. Remove the flange, plates and discs.
5. Place special tool on the spring retainer and
compress the return spring.
Using snap ring pliers, remove the snap ring.
Spring compressor : J–25048

248RY00029

248RY00002

6. Remove the piston return spring.

7A4–60 UNIT REPAIR (AW30–40LE)
7. Place the direct clutch drum onto the OD support. 2. Check discs.
Holding the direct clutch piston by hand, apply Using micrometer, measure the thickness of the
compressed air to the OD support to remove the discs.
direct clutch piston.
Minimum thickness: 2.04mm (0.0803in)
Remove the direct clutch piston from direct clutch
drum. If the thickness is less than the minimum, replace
the disc.

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248RY00030

8. Remove two O-rings from piston. 252RY00027

3. Check direct clutch piston.

Check that check ball is free by shaking the piston.
Inspection and Repair Check that the valve does not leak by applying
1. Check piston return spring. low-pressure compressed air.
Using calipers, measure the free length of the return
spring.
Standard length: 21.3mm (0.839in)

248RY00031

247RY00034
 UNIT REPAIR (AW30–40LE) 7A4–61
4. Check direct clutch drum bushing. 3. Install piston return spring.
Using a dial indicator, measure the inside diameter
of the clutch drum bushing.
Maximum inside diameter: 53.99mm (2.1256in)
If the inside diamater is greater than the maximum,
replace the clutch drum.

248RY00034

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4. Compress piston return spring and install snap ring
in groove.
• Place special tool on the spring retainer, and
compress the return spring.
• Install the snap ring with snap ring pliers.
248RY00032

• Be sure the end gap of the snap ring is not

Reassembly aligned with the spring retainer claw.
Spring compressor: J–25048
1. Coat new O-rings with ATF and install them on the
direct clutch piston.
2. Install direct clutch piston to direct clutch drum.
Being careful not to damage the O-rings, press in
the direct clutch piston into the clutch drum, using
both hands.

248RY00002

248RY00033
7A4–62 UNIT REPAIR (AW30–40LE)
5. Install four plates and four discs. 7. Install the snap ring with a screwdriver.
Install in order : P–D–P–D–P–D–P–D Be sure the end gap of the snap ring is not aligned
P : Plate, D : Disc with the cutout portion of the direct clutch drum.

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248RY00062 248RY00036

6. Install the flange, with the flat side facing downward. 8. Check piston stroke of direct clutch (C–2).
Place the direct clutch assembly onto the OD
support assembly.

248RY00035

248RY00029

Using a dial indicator, measure the direct clutch

piston stroke by applying and releasing compressed
air (390 – 780 kPa or 57 – 114 psi) as shown.
Pack clearance: 0.4 – 0.7 mm (0.016 – 0.028 in)
If the piston stroke is not within specification,
replace the discs and recheck the piston stroke.
If the piston stroke is nonstandard, select another
flange.
 UNIT REPAIR (AW30–40LE) 7A4–63
Flange sizes Align the flukes of discs in the direct clutch.
Flange thickness Flange thickness Install the direct clutch assembly onto the forward
clutch assembly.
3.3mm (0.130in) 3.8mm (0.150in)
Check that the distance from the direct clutch end to
3.4mm (0.134in) — the forward clutch end is 71.2mm (2.803in).
3.5mm (0.138in) 4.0mm (0.157in)
3.6mm (0.142in) —
3.7mm (0.146in) 4.2mm (0.165in)

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248RY00038

RUW37ASH004901

9. Coat the clutch drum thrust washer (plastic) with

petroleum jelly and install it onto the direct clutch.
NOTE: Make sure that the lugs fit into the cutout
portions on the direct clutch.

248RY00037
7A4–64 UNIT REPAIR (AW30–40LE)

Forward Clutch Asseembly (C-1)

Disassembled View

Legend (7) Snap ring

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248R200003

(1) Thrust bearing (8) Piston return spring

(2) Race (9) Piston
(3) Snap ring (10) O-ring
(4) Flange (11) O-ring
(5) Disc and plate (12 Oil seal ring
Six discs and six plates (13) Thrust bearing
(6) Cushion plate (14) Forward clutch drum
E nd O FCallo ut
 UNIT REPAIR (AW30–40LE) 7A4–65

Disassembly 2. Check piston stroke of forward clutch (C–1).

Remove forward clutch assembly from direct clutch

assembly.

248R200008

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Using a dial indicator, measure the forward clutch
piston stroke by applying and releasing compressed
248RY00039 air (390 – 780 kPa or 57 – 114 psi) as shown.
1. Place wooden blocks, etc. to prevent forward clutch Pack clearance: 0.5 – 0.9 mm (0.020 – 0.035 in)
shaft from touching the work stand, and place the
OD support on them. 3. Remove snap ring from clutch drum.
Place the forward clutch onto the OD support and
remove the bearing and race.

248RY00041

4. Remove the flange, disc and plate, and cushion

248RY00048
plate.
7A4–66 UNIT REPAIR (AW30–40LE)
5. Place special tool on the spring retainer and
compress the return spring.
Using snap ring pliers, remove the snap ring.
Spring compressor : J–25048

248RY00031

2. Check forward clutch drum bushing.

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Using a dial indicator, measure the inside diameter
of the forward clutch drum bushing.
248RY00003
Maximum inside diameter: 24.08mm (0.948in)
6. Remove the piston return spring.
7. Place the forward clutch drum onto the OD support. If the inside diameter is greater then the maximum,
Holding the forward clutch piston by hand, apply replace the forward clutch drum.
compressed air to the OD support to remove the
forward clutch piston.

248RY00043

3. Check disc, plate and flange.

248RY00042
Check to see if the sliding surface of the disc, plate
8. Remove the O-rings from piston. and flange are worn or burnt. If necessary, replace
them.
9. Remove the O-ring from forward clutch drum.
• If the lining of the disc is peeling off or discolored,
10. Remove the oil seal rings and thrust bearing from
or even if parts of the printed numbers are
forward clutch drum.
defaced, replace all discs.

Inspection and Repair

1. Check forward clutch piston
Check that check ball is free by shaking the piston.
Check that the valve does not leak by applying
low-pressure compressed air.
 UNIT REPAIR (AW30–40LE) 7A4–67
• Before assembling new discs, soak them in ATF Reassembly
for at least fifteen minutes.
1. Coat the assembled thrust bearing and race with
petroleum jelly and install it onto the forward clutch
drum, with the race side facing downward.
Bearing and race (Reference)
Inside diameter 33.7mm (1.327in)
Outside diameter 47.8mm (1.882in)

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248RY00045

4. Check piston return spring.

Using calipers, measure the free length of the return
spring.
Standard length: 19.47mm (0.7665in)

248RY00044

2. Coat the three oil rings with ATF.

Contract the oil seal rings as shown, and install
three oil seal rings onto the forward clutch drum.
NOTE: Do not spread the ring ends more than
necessary.

247RY00034

248RY00046
7A4–68 UNIT REPAIR (AW30–40LE)
3. Coat a new O-ring with ATF and install O-ring on the 6. Install piston return spring.
forward clutch drum.

248RY00065

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248RY00047 7. Place special tool on the spring retainer, and
4. Coat new O-rings with ATF and install two O-rings compress the return spring.
on the forward clutch piston. Spring compressor: J–25048
5. Being careful not to damage the O-rings, press the Install the snap ring with snap ring pliers.
forward clutch piston into the forward clutch drum. Be sure the end gap of the snap ring is not aligned
with the spring retainer claw.

248RY00049

248RY00003
 UNIT REPAIR (AW30–40LE) 7A4–69
8. Install cushion plate rounded side down as shown. 11. Install the snap ring with a screwdriver.
Be sure the end gap of the snap ring is not aligned
with the cutout portion of the forward clutch drum.

248RY00069

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9. Install five discs and five plates.
Install in order: P–D–P–D–P–D–P–D–P–D 248RY00041

10. And then install the flange, with the rounded edge 12. Check piston stroke of forward clutch (C–1).
facing downward. Using a dial indicator, measure the forward clutch
piston stroke by applying and releasing the
compressed air (380 – 780 kPa or 57 – 114 psi) as
shown.
Pack clearance: 0.5 – 0.9 mm (0.020 – 0.035 in)
If the piston stroke is not within specification,
replace the discs, and recheck the piston stroke.
Available flange sizes
3.0mm (0.118in) 3.4mm (0.134in)
4.2mm (0.165in) 3.6mm (0.142in)
4.4mm (0.173in) 3.8mm (0.150in)
3.2mm (0.126in) 4.0mm (0.158in)

248RY00070

248R200008
7A4–70 UNIT REPAIR (AW30–40LE)
13. Coat the race and thrust bearing with petroleum Check that the distance from the direct clutch end to
jelly, and install them onto the forward clutch drum. the forward clutch end is 71.2mm (2.803in).
Race and bearing diameter (Reference)
Inside Outside
Race 26.0mm (1.024in) 48.9mm (1.925in)
Bearing 26.0mm (1.024in) 46.7mm (1.839in)

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248RY00038

248RY00048

14. Align the flukes of discs in the direct clutch.

Install the direct clutch assembly onto the forward
clutch assembly.

248RY00039
 UNIT REPAIR (AW30–40LE) 7A4–71

Front Planetary Gear

Disassembled View

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247R200003

Legend (5) Race (Metal)

(1) Race (6) Thrust bearing
(2) Thrust bearing (7) Race
(3) Race (8) Front planetary ring gear
(4) Front planetary gear
E nd O FCallo ut

Disassembly
1. Remove the race from front planetary ring gear.
2. Remove the thrust bearing and race from front
planetary gear.
3. Remove the race (Metal), thrust bearing and race
between front planetary ring gear and front
planetary gear.

Inspection and Repair

1. Check front planetary ring gear bushing
Using a dial indicator, measure the inside diameter
of the front planetary ring gear bushing.
Maximum inside diameter: 24.08mm (0.9480in)
If the inside diameter is greater than the maximum,
replace the front planetary ring gear.
247RY00021
7A4–72 UNIT REPAIR (AW30–40LE)

Reassembly 3. Coat the race and thrust bearing with petroleum

jelly.
1. Coat the race and thrust bearing with petroleum Install the race and bearing onto the rear side of the
jelly. front planetary ring gear.
Install the race and bearing to the rear side of the Race and bearing diameter (Reference)
front planetary gear. Inside Outside
Race and bearing diameter (Reference)
Race 35.15 mm (1.38 in) 53.65 mm (2.11 in)
Inside Outside
Bearing 35.15 mm (1.38 in) 53.65 mm (2.11 in)
Bearing 35.6mm (1.402in) 47.7mm (1.878in)
Race 33.7mm (1.327in) 47.6mm (1.874in)

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247RY00025

4. Turn over the planetary ring gear and install the race
247RY00023 onto the front side of the front planetary ring gear.
2. Turn over the planetary gear and install the race Race diameter (Reference)
(metal). Inside Outside
Make sure that the lugs fit into the holes on the front
planetary gear. Race 26.8mm (1.055in) 47.0mm (1.850in)
Race diameter (Reference)
Inside Outside
Race 34.3mm (1.350in) 47.8mm (1.882in)

247RY00026

247RY00024
 UNIT REPAIR (AW30–40LE) 7A4–73

Planetary Sun Gear and No.1 One-Way Clutch

Disassembled View

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248R200005

Legend (4) Snap ring

(1) One-way clutch and second brake hub (5) Sun gear input drum
(2) Thrust washer (plastic) (6) Snap ring
(3) Oil seal ring (Metal) (7) Planetary sun gear
E nd O FCallo ut
7A4–74 UNIT REPAIR (AW30–40LE)

Disassembly 5. Remove the snap ring with snap ring pliers.

1. Check operation of No.1 one-way clutch

Hold the planetary sun gear and turn the second
brake hub.
The second brake hub should turn freely clockwise
and should lock counterclockwise.

248RY00053

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6. Remove the sun gear input drum.
7. Remove the snap ring from planetary sun gear.

Inspection and Repair

RUW37ASH004601
1. Check planetary sun gear bushing
Legend Using a dial indicator, measure the inside diameter
(1) Free of the planetary sun gear bushing.
(2) Lock
E nd OFCa llou t
Maximum inside diameter: 27.08 mm (1.066 in)
If the inside diameter is greater than the maximum,
2. Remove the one-way clutch and second brake hub.
replace the planetary sun gear.
3. Remove the trust washer (plastic).
4. Remove two oil seal rings (metal).

248RY00054

248RY00052
 UNIT REPAIR (AW30–40LE) 7A4–75

Reassembly 3. Install snap ring with snap ring pliers.

1. Install snap ring to planetary sun gear.

248RY00053

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4. Coat the two oil seal rings (metal) with ATF.
248RY00055 Install the two oil seal rings onto the planetary sun
2. Place a wooden block, etc. as a work stand and gear.
place the planetary sun gear onto it.
NOTE: Do not spread the ring ends too much.
Install the sun gear input drum onto the planetary
sun gear.

248RY00052

248RY00056
7A4–76 UNIT REPAIR (AW30–40LE)
5. Install thrust washer (plastic). 7. Check operation of No.1 one-way clutch
Hold the planetary sun gear and turn the second
NOTE: Make sure that the lugs fit into the holes on the
brake hub.
sun gear input drum.
The second brake hub should turn freely clockwise
and should lock counterclockwise.

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248RY00057

6. Install assembled No.1 one-way clutch and second

RUW37ASH004601
brake hub onto planetary sun gear as shown.
Legend
(1) Free
(2) Lock
E nd OFCa llou t

248RY00058
 UNIT REPAIR (AW30–40LE) 7A4–77

Second Brake Assembly (B–2)

Disassembled View

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246R200001

Legend (5) Piston return spring

(1) Second brake assembly (6) Piston sleeve
(2) Thrust washer (Plastic) (7) Second brake piston
(3) Snap ring (8) O-ring
(4) Spring retainer (9) Second brake drum
E nd O FCallo ut

Disassembly
1. Remove second brake assembly from output shaft.

246RY00007
7A4–78 UNIT REPAIR (AW30–40LE)
2. Remove the hrust washer (plastic). Inspection and Repair
3. Place special tool on the spring retainer, and
compress the return spring. 1. Check piston return spring.
Spring compressor: J–25048 Using calipers, measure the free length of the return
Remove the snap ring with snap ring pliers. spring.
Standard length: 18.38 mm (0.724 in)

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247RY00001

4. Remove the spring retainer and piston return spring. 247RY00034

5. Romove piston sleeve.

6. Holding the second brake piston by hand, apply Reassembly
compressed air to the second brake drum to remove
1. Coat new O-rings with ATF and install them on the
the second brake piston.
second brake piston.
Remove the second brake piston from the second
brake drum.

246RY00009

2. Being careful not to damage the O-rings, press in

246RY00008
the second brake piston into the second brake
7. Remove the o-rings from the second brake piston.
drum.
3. Install piston sleeve.
 UNIT REPAIR (AW30–40LE) 7A4–79
4. Install piston return spring. 7. Check second brake piston movement.
Make sure the second brake piston moves smoothly
when applying and releasing the low compressed
air to the second brake drum.

246RY00010

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5. Install spring retainer.
6. Place special tool on the spring retainer, and
compress the return spring. 246RY00011

Spring compressor: J–25048 8. Coat the thrust washer (plastic) with petroleum jelly
Install the snap ring with snap ring pliers. and install it to the second brake piston, with the
Be sure the end gap of the snap ring is not aligned grooved side facing upward.
with the spring retainer claw. NOTE: Make sure that the cutout portions of the thrust
washer match the teeth of the spring retainer.

247RY00001

246RY00012
7A4–80 UNIT REPAIR (AW30–40LE)
9. Install second brake assembly to output shaft.

246RY00014

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 UNIT REPAIR (AW30–40LE) 7A4–81

Rear Planetary Gear Assembly and Output Shaft

Disassembled View

Legend (8) One-way clutch

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247R200005

(1) Second brake assembly (9) Thrust washer (Plastic)

(2) Output shaft (10) Thrust washer (Plastic)
(3) Oil seal ring (11) Rear planetary gear
(4) Disc, plate and flange (B–3) (12) Thrust bearing and race
Seven discs and seven plates (13) Snap ring
(5) Rear planetary gear assembly (14) Ring gear flange
(6) One-way clutch inner race (15) Rear planetary ring gear
(7) Snap ring
E nd O FCallo ut
7A4–82 UNIT REPAIR (AW30–40LE)

Disassembly 4. Remove rear planetary gear from rear planetary ring

gear.
1. Remove second brake assembly from output shaft.

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247RY00029

246RY00014 5. Check operation of No.2 one-way clutch.

2. Remove oil seal ring from output shaft. Hold the planetary gear and turn the one-way clutch
inner race.
The one-way clutch inner race should turn freely
counterclockwise and should lock clockwise.

247RY00028

3. Remove the seven discs, seven plates and flange

(B–3).
RUW37ASH004701

Legend
(1) Lock
(2) Free
E nd OFCa llou t
 UNIT REPAIR (AW30–40LE) 7A4–83
6. Remove the one-way clutch inner race from the rear 8. Remove the one-way clutch with retainers from the
planetary gear. planetary gear.

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247RY00031 247RY00033

7. Remove the snap ring with a screwdriver. 9. Remove the thrust washer (plastic) from front side
of rear planetary gear.
10. Remove the thrust washer (plastic) from rear side of
rear planetary gear.
11. Remove the thrust bearing and race from front side
of ring gear flange.
12. Remove the snap ring from rear planetary ring gear.
13. Remove the ring gear flange from rear planetary
ring gear.
14. Check disc, plate and flange.
Check to see if the sliding surface of the disc, plate
and flange are worn or burnt. If necessary, replace
them.
• If the lining of the disc is peeling off or discolored,
or even if parts of the printed numbers are
defaced, replace all discs.
• Before assembling new discs, soak them in ATF
for at least fifteen minutes.
247RY00032

248RY00045
7A4–84 UNIT REPAIR (AW30–40LE)

Reassembly
1. Install ring gear flange to the rear planetary ring
gear.
2. Install snap ring to the rear planetary ring gear.

247RY00037

5. Install the one-way clutch with the flanged side

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facing upward onto the rear planetary gear.

247RY00035

3. Coat the races and bearing with petroleum jelly, and

install them onto the rear planetary ring gear.
Races and bearing diameter (Reference)
Inside Outside
Race (A) 28.5mm (1.122in) 44.2mm (1.740in)
Bearing and 27.7mm (1.091in) 44.2mm (1.740in)
race (B)

247RY00038

6. Install snap ring.

247RY00036

4. Coat the thrust washers (plastic) with petroleum

jelly.
Install the thrust washers onto both sides of the rear
planetary gear, facing the grooved side upward.
NOTE: Make sure that the lugs fit into the cutout
portions on the rear planetary gear.

247RY00039
 UNIT REPAIR (AW30–40LE) 7A4–85
7. While turning counterclockwise, install one-way 9. Install rear planetary gear onto rear planetary ring
clutch inner race to rear planetary gear. gear.

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247RY00040 247RY00029

8. Check operation of one-way clutch. 10. Install the disc, plate and flange (B–3).
Hold the planetary gear and turn the one-way clutch • Install a brake flange onto the rear planetary gear
inner race. assembly.
The one-way clutch inner race should turn freely
• Install a clutch disc onto the rear planetary gear
counterclockwise and should lock clockwise.
assembly.
NOTE: The claw interval of the plate should be as
shown in the figure when viewing the clutch plate from
the arrow direction.

RUW37ASH004701

Legend
(1) Lock
(2) Free
E nd OFCa llou t
246RY00013
7A4–86 UNIT REPAIR (AW30–40LE)
• Install six clutch discs and six brake plates 12. Install output shaft into rear planetary gear
alternately, starting with clutch disc, onto the rear assembly.
planetary gear assembly.

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247RY00042

247RY00047 13. Install second brake assembly to output shaft.

11. Coat the oil seal ring with ATF and install it to the
output shaft.
NOTE: Do not spread the ring ends too much.

246RY00014

247RY00028
 UNIT REPAIR (AW30–40LE) 7A4–87

First and Reverse Brake (B–3)

Disassembled View

Legend (5) O-ring

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246RY00024

(1) Thrust bearing and race (6) Reaction sleeve

(2) Snap ring (7) O-ring
(3) Piston return spring (8) First and reverse brake piston No.1
(4) First and reverse brake piston No.2 (9) O-ring
E nd O FCallo ut
7A4–88 UNIT REPAIR (AW30–40LE)

Disassembly 3. Set special tool on the spring retainer, and

compress the return spring.
1. Remove assembled thrust bearing and race from Spring compressor: J–25048
transmission case. Remove the snap ring with snap ring pliers.

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247RY00043 247RY00002

2. Check first and reverse brake piston movement. 4. Remove the piston return spring.
Make sure that first and reverse brake piston moves 5. Remove the first and reverse brake piston No.2.
smoothly when applying and releasing the Holding the first and reverse brake piston No.2 by
compressed air into the transmission case. hand, apply compressed air to the transmission
case to remove the first and reverse brake piston
No.2.
Remove the first and reverse brake piston No.2.
If the piston does not pop out with compressed air,
lift the piston out with needle-nose pliers.

246RY00016

246RY00016
 UNIT REPAIR (AW30–40LE) 7A4–89
6. Remove the O-ring from first and reverse brake Reassembly
piston No.2.
7. Remove the reaction sleeve. 1. Coat three new O-rings with ATF.
Insert special tool behind the reaction sleeve and Install the two O-rings on the No.1 piston.
gradually lift it out of the transmission case. 2. Install the O-ring on the reaction sleeve.
Reaction sleeve puller: J–37236 3. Install the first and reverse brake piston No.1 to the
reaction sleeve.

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RUW37ASH003301

8. Remove the O-ring from reaction sleeve. 246RY00018

9. Remove the first and reverse brake piston No.1. 4. Coat a new O-ring with ATF and install it on the first
Insert special tool behind the first and reverse brake and reverse brake piston No.2.
piston No.1 and gradually lift it out of the 5. Install the first and reverse brake piston No.1 with
transmission case. reaction sleeve onto the first and reverse brake
Piston puller: J–37237 piston No.2.

RUW37ASH003401 246RY00019

10. Remove the O-rings from first and reverse brake

pistion No.1.
7A4–90 UNIT REPAIR (AW30–40LE)
6. Align the teeth of the first and reverse brake piston 8. Set special tool as shown, and compress the return
No.2 into the proper grooves. spring with special tool.
Being careful not to damage the O-rings, press in Spring compressor: J–25048
the first and reverse brake piston No.2 with No.1 Install the snap ring with snap ring pliers.
into the transmission case. Be sure the end gap of the snap ring is not aligned
with the spring retainer claw.

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246RY00020

7. Place piston return spring onto first and reverse 247RY00002

brake piston No.2. 9. Check first and reverse brake piston movement.
Make sure the first and reverse brake piston moves
smoothly when applying and releasing the
compressed air into the transmission case.

246RY00021

246RY00022
 UNIT REPAIR (AW30–40LE) 7A4–91
10. Coat the assembled bearing and race with
petroleum jelly.
Install the assembled bearing and race facing the
bearing side upward.
Bearing and race diameter (Reference)
Inside diameter 39.38mm (1.550in)
Outside diameter 58.15mm (2.289in)

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247RY00043
7A4–92 UNIT REPAIR (AW30–40LE)

Transmission Valve Body assembly

Disassembled View

Legend (5) Valve body plate

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240R200039

(1) Detent spring (6) Clamp

(2) Manual shift valve (7) Pressure control solenoid
(3) Upper valve body (8) No.2 gasket (Lower valve body side)
(4) No.1 gasket (Upper valve body side) (9) Lower valve body
E nd O FCallo ut
 UNIT REPAIR (AW30–40LE) 7A4–93

Disassembly 7. Remove the pressure control solenoid.

Hold the valve body plate to the upper valve body.
1. Remove detent spring from valve body. Lift off upper valve body and plate as a single unit.
NOTE: Be careful that the check balls and strainers do
not fall out.

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240R200040

2. Remove the manual shift valve.

3. Remove the upper valve body. 244R200061

4. Remove the no.1 gasket (Upper valve body side). 8. Remove the no.2 gasket (Lower valve body side).
5. Remove the valve body plate. 9. Remove the lower valve body.
• Turn over assembly and remove thirty bolts.
Reassembly
1. Position a new No.1 gasket (1) on upper valve body.
Align the No.1 gasket at each bolt hole.
2. Position valve body plate (2) on No.1 gasket (1).
Align the plate at each bolt hole.
3. Position a new No.2 gasket (3) on valve body plate
(2).
Align the No.2 gasket at each bolt hole.

244R200049

6. Remove the clamp.

244R200073
7A4–94 UNIT REPAIR (AW30–40LE)
4. Place upper valve body with plate and gaskets on 5. Install the pressure control solenoid and clamp.
top of lower valve body. 6. Install thirty bolts to upper valve body.
Align each bolt hole and gasket in the valve body. Each bolt is indicated in the figure.
Length (mm) Quantity
A 20 7
B 28 12
C 40 11
Torque: 6.4N·m (57Ibin)

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244R200074

244R200050

7. Install manual shift valve.

 UNIT REPAIR (AW30–40LE) 7A4–95
8. Install detent spring.
Torque: 10N·m (87Ibin)

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240R200040
7A4–96 UNIT REPAIR (AW30–40LE)

Lower Valve Body

Cross Section

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RUW37AMF001901
 UNIT REPAIR (AW30–40LE) 7A4–97
Disassembled View

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244R200075

Legend (18) Low coast modulator valve

(1) By-pass valve (19) Retainer
(2) Spring (20) Plug
(3) Strainer (21) Spring
(4) Shift solenoid S1 (22) Accumulator control valve
(5) Shift solenoid S2 (23) Retainer
(6) Lock-up solenoid SL (24) Spring
(7) Clamp (25) Solenoid modulator valve
(8) Accumulator sub-assembly (26) Retainer
(9) Retainer (27) Plug
(10) Spring (28) Spring
(11) Ball (29) Cut back valve
(12) Retainer (30) Retainer
(13) Plug (31) Sleeve
(14) Spring (32) Plunger
(15) 1–2 shift valve (33) Plunger
(16) Retainer (34) Spring
(17) Spring (35) Washer
(36) Primary regulator valve
7A4–98 UNIT REPAIR (AW30–40LE)

(37) Lower valve body

E nd O FCallo ut

Disassembly NOTE: Confirm six retainers are installed correctly.

1. Remove by-pass valve and spring.

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244R200066

3. Remove the shift solenoid S1 and shift solenoid S2.

244R200063
• Remove the fixing bolt.
2. Remove three strainers.
• Remove the shift solenoid S1 (2) and S2 (1) from
each bore.
• Remove the O-rings from each solenoid.
4. Remove the lock-up solenoid SL
• Remove the fixing bolt.
• Remove the lock-up solenoid SL (3) from the
bore.
• Remove the O-ring from solenoid.
5. Remove the accumulator sub-assembly
• Remove the clamp.
• Remove the accumulator sub-assembly (4) from
the bore.

244R200064
 UNIT REPAIR (AW30–40LE) 7A4–99
6. Remove the retainer (5).
Remove the spring and ball from the valve body.

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244R200052

240R200042
7A4–100 UNIT REPAIR (AW30–40LE)
7. Remove the 1–2 shift valve retainer (12) with a 9. Remove the retainer (16) for low coast modulator
magnetic finger by pushing the plug. valve by pushing the spring with a screwdriver.

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244R200067 244R200068

8. Remove the plug, spring and 1–2 shift valve. 10. Remove the spring and low coast modulator valve.

244R200054 244R200056
 UNIT REPAIR (AW30–40LE) 7A4–101
11. Remove the retainer (19) for accumulator control 13. Remove the retainer (23) for solenoid modulator
valve with a magnetic finger by pushing the plug. valve(25) by pushing the spring with a screwdriver.

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244R200069 244R200070

12. Remove the plug(20), spring(21) and accumulator 14. Remove the spring(24) and solenoid modulator
control valve(22). valve(25).

244R200057 244R200058
7A4–102 UNIT REPAIR (AW30–40LE)
15. Remove the retainer(26) for cut back valve(29) with 17. Place a mark on the top of sleeve(31) and the
a magnetic finger by pushing the plug. retainer (30) for primary requlator valve(36) where
they are positioned.

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244R200071

16. Remove the plug(27), spring(28) and cut back 244R200059

valve(29). NOTE: When reassembling, position the retainer in the

same position.
Remove the retainer(30) with a magnetic finger by
pushing the sleeve.

244R200065

244R200072
 UNIT REPAIR (AW30–40LE) 7A4–103
18. Remove the sleeve(31) with the plungers(32)(33), 2. Inspect valve springs
spring(34) and washer. Check for damage, squareness, rust and distorted
Remove the two plungers(32)(33) from the sleeve. coils.
Remove the primary regulator valve(36) from the Measure the spring free length and replace if less
valve body(37). than shown below.
mm (in)
Free
Spring Color
length
21.3
(1) By-pass valve YELLOW
(0.839)
20.5
(2) Steel ball WHITE
(0.807)
30.8
(3) 1–2 shift valve PURPLE
(1.213)
30.4 LIGHT
(4) Low coast modulator valve
(1.197) GREEN
33.8
(5) Accumulator control valve —
(1.331)

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26.6 LIGHT
(6) Solenoid modulator valve
(1.047) BLUE
34.0 DARK
244R200060 (7) Cut back valve
(1.339) BLUE
38.58
Inspection and Repair (8) Primary regulator valve
(1.519)
WITHE
1. Inspect strainer
Inspect strainer for residual adhesive and damage,
and clean and replace as necessary.

244R200051

244R200077
7A4–104 UNIT REPAIR (AW30–40LE)

Reassembly NOTE: Install the retainer (30) to the same position on

the top of sleeve(31), as when disassembling.
1. Install the washer(35) onto the primary regulator
valve(36).
Install the primary regulator valve(36) with the
washer(35) into the bore of lower valve body.
Install the two plungers(32)(33) into the sleeve(31).
Align the mark on the top of sleeve(31) with the
mark on the retainer(30).
Install the sleeve(31) with the two plungers(32)(33)
and spring(34) into the bore.

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244R200059

3. Install the cut back valve(29), spring(28) and

plug(27) into the bore.

244R200060

2. Install the retainer(30) by pushing the sleeve.

244R200065

244R200072
 UNIT REPAIR (AW30–40LE) 7A4–105
4. Install the retainer(26) by pushing the plug. 6. Install the retainer(23) by pushing the spring.

244R200071 244R200070

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5. Install the coast modulator valve(25) and spring(24) 7. Install the accumulator control valve(22), spring(21)
into the bore. and plug(20) into the bore.

244R200058 244R200057
7A4–106 UNIT REPAIR (AW30–40LE)
8. Install the retainer(19) by pushing in the plug. 10. Install the retainer(16) by pushing the spring.

244R200069 244R200068

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9. Install the low coast modulator valve(18) and 11. Install the 1–2 shift valve(15), spring(14) and
spring(17) into the bore. plug(13) into the bore.

244R200056 244R200054
 UNIT REPAIR (AW30–40LE) 7A4–107
12. Install the retainer(12) by pushing the plug. 16. Install a new O-ring to the shift solenoid S2 (5) and
shift solenoid S1 (4).
Install the solenoids to the valve body.
Torque: 10N·m (87Ibin)

244R200067

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13. Install the ball(11), spring(10) and retainer (9) to the
valve body.
Torque: 6.9 N·m (60Ibin) RUW37AMH000401

Legend
(4) Shift Solenoid S1
(5) Shift Solenoid S2
(6) Lock-up Solenoid SL
(8) Accumulator Sub-assembly
(9) Retainer
E nd OFCa llou t

NOTE: Make sure six retainers are installed correctly.

244R200052

14. Install the accumulator sub-assembly (8) and

clamp(7) to the valve body.
Torque: 10N·m (87Ibin)
15. Install a new O-ring to the lock-up solenoid SL (6).
Install the solenoid to the valve body.
Torque: 10N·m (87Ibin)

244R200066
7A4–108 UNIT REPAIR (AW30–40LE)
17. Install the three strainers(3) to the valve body as
shown.

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244R200064

18. Install the spring(2) and by-pass valve(1) to the

valve body as shown.

244R200063
 UNIT REPAIR (AW30–40LE) 7A4–109

Upper Valve Body

Cross Section

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243R200052
7A4–110 UNIT REPAIR (AW30–40LE)
Disassembled View

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243R200074

Legend (18) Retainer

(1) Check ball (19) Plug
(2) Retainer (20) Spring
(3) Check valve NO.2 (21) Reverse control valve
(4) Ball (22) Retainer
(5) Check valve NO.1 (23) Plug
(6) Retainer (24) Second coast modulator valve
(7) Check valve NO.2 (25) Spring
(8) Ball (26) Retainer
(9) Check valve NO.1 (27) Plug
(10) Retainer (28) 3–4 shift valve
(11) Plug (29) Spring
(12) Secondary regulator valve (30) Retainer
(13) Spring (31) Sleeve
(14) Retainer (32) Plunger
(15) Plug (33) Spring
(16) Spring (34) Lock-up relay valve
(17) 2–3 shift valve (35) Upper valve body
E nd O FCallo ut
 UNIT REPAIR (AW30–40LE) 7A4–111

Disassembly 2. Remove the ratainer (2) for check valve.

1. Remove the two types of check balls(1) from the

valve body.
Number of check ball : 11

243R200066

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3. Remove the check valve NO.2(3), ball(4) and check
valve NO.1(5) from the valve body.

RUW37ASH004801

NOTE: Confirm eight retainers are installed correctly.

243R200062

243R200054
7A4–112 UNIT REPAIR (AW30–40LE)
4. Remove the retainer (6) for check valve. 6. Remove the retainer (10) for secondary regulator
valve with a magnetic finger by pushing the plug.

243R200067

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5. Remove the check valve NO.2(7), ball(8) and check 243R200070

valve NO.1(9) from the valve body. 7. Remove the plug(11), secondary regulator valve(12)
and spring(13).

243R200062

243R200056
 UNIT REPAIR (AW30–40LE) 7A4–113
8. Remove the retainer (14) for 2–3 shift valve with a 10. Remove the retainer (18) for reverse control valve
magnetic finger by pushing the plug. with a magnetic finger by pushing in the plug.

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243R200069 243R200068

9. Remove the plug(15), spring(16) and 2–3 shift 11. Remove the plug(19), spring(20) and reverse
valve(17). control valve(21).

243R200058 243R200060
7A4–114 UNIT REPAIR (AW30–40LE)
12. Remove the retainer (22) for second coast 14. Remove the retainer (26) for 3–4 shift valve with a
modulator valve with a magnetic finger by pushing magnetic finger by pushing the plug.
the plug.

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243R200072

243R200073 15. Remove the plug(27), 3–4 shift valve(28) and

13. Remove the plug(23), second coast modulator spring(29).
valve(24) and spring(25).

243R200064

243R200063
 UNIT REPAIR (AW30–40LE) 7A4–115
16. Remove the retainer (30) for lock-up relay valve with Inspection and Repair
a magnetic finger by pushing in the sleeve.
1. Inspect valve springs
Check for damage, squareness, rust and distorted
coils.
Measure the spring free length and replace if less
than below.
mm (in)
Free
Spring Color
length
32.9
(1) Secondary regulator valve PURPLE
(1.295)
30.8
(2) 2–3 shift valve PURPLE
(1.213)
25.6
(3) Reverse control valve —
(1.008)
(4) Second coast modulator 25.3
ORANGE
valve (0.996)
30.8

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243R200071 (5) 3–4 shift valve PURPLE
17. Remove the sleeve(31) with the plunger(32), (1.213)
spring(33) and lock-up relay valve(34). 23.4
(6) Lock-up relay valve RED
Remove the lock-up relay valve(34), spring(33) and (0.912)
plunger(32) from the sleeve(31).

243R200065

243R200076
7A4–116 UNIT REPAIR (AW30–40LE)

Reassembly 3. Install the spring, 3-4 shift valve(28) and plug(27)

into the bore.
1. Install the plunger(32) and spring(33) into the
sleeve(31).
Install the lock-up relay valve(34) into the
sleeve(31).
Install the sleeve(31) with the plunger(32),
spring(33) and lock-up relay valve(34) into the bore.

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243R200064

4. Install the retainer(26) by pushing the plug.

243R200065

2. Install the retainer(30).

243R200072

243R200071
 UNIT REPAIR (AW30–40LE) 7A4–117
5. Install the spring(25), second coast modulator 7. Install the reverse control valve(21), spring(20) and
valve(24) and plug(23) into the bore. plug(19) into the bore.

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243R200063 243R200060

6. Install the retainer(22) by pushing the plug. 8. Install the retainer(18) by pushing the plug.

243R200073 243R200068
7A4–118 UNIT REPAIR (AW30–40LE)
9. Install the 2–3 valve(17), spring(16) and plug(15) 11. Install the spring(13), secondary regulator valve(12)
into the bore. and plug(11) into the bore.

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243R200058 243R200056

10. Install the retainer(14) by pushing the plug. 12. Install the retainer(10) by pushing the plug.

243R200069 243R200070
 UNIT REPAIR (AW30–40LE) 7A4–119
13. Install the check valve NO.1(9), ball(8) and check 15. Install the check valve NO.1(5), ball(4) and check
valve NO.2(7) to valve body. valve NO.2(3) to the valve body.

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243R200062 243R200062

14. Install the retainer(6). 16. Install the retainer(2).

243R200067 243R200066
7A4–120 UNIT REPAIR (AW30–40LE)
NOTE: Make sure eight retainers are installed correctly

243R200054

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17. Install the two types of check balls(1) to the valve
body.
Number of check ball : 11
Check ball Diameter
(A) Rubber ball 5.535mm (0.2179in
(B) Rubber ball 6.35mm (0.2500in

RUW37ASH004801
 UNIT REPAIR (AW30–40LE) 7A4–121

Transmission Case

Disassembled View

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249RY00001

Legend (4) Manual valve lever

(1) Spacer (5) Oil seal
(2) Pin (6) Oil seal
(3) Manual valve lever shaft
E nd O FCallo ut

Disassembly
1. Using a chisel, cut off the spacer and remove it from
the shaft.

249RY00002
7A4–122 UNIT REPAIR (AW30–40LE)
2. Using a punch, drive out the pin. Reassembly
1. Coat a new oil seal lip with multi purpose grease.
Using special tool, drive in the oil seal.
Oil seal installer : J–37232–2

249RY00003

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3. Pull the manual valve lever shaft out through the
case by the threads.
4. Take out the manual valve lever.
RTW37ASH000701
5. Using a screwdriver, remove the oil seals.
2. Assemble a new spacer to the manual valve lever.
3. Install the manual valve lever shaft to the
transmission case through the manual valve lever
by the threads.

249RY00004

249RY00005
 UNIT REPAIR (AW30–40LE) 7A4–123
4. Drive in the pin with the slot at a right angle to the
shaft.

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249RY00006

5. Match the spacer hole to the lever staking hollow

and stake the spacer to the lever.
Make sure the manual valve lever shaft turns
smoothly.

249RY00003
7A4–124 UNIT REPAIR (AW30–40LE)

Torque Converter

Inspection and Repair

Insert special tool in end of torque converter.
Insert a turning tool into the inner race of the one-way
clutch.
One-way clutch testing tool : J–35467
Insert the stopper so that it fits in the notch of the
converter hub and outer race of the one-way clutch.

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RUW37ASH003501

1. One-way clutch test.

The clutch should lock when turned
counterclockwise, and rotate freely and smoothly
clockwise. Less than 2.5N·cm (22Ibin) of torque
should be required to rotate the clutch clockwise. If
necessary, clean the converter and retest the clutch.
Replace the converter if the clutch still fails the test.
 UNIT REPAIR (AW30–40LE) 7A4–125

Adapter Housing (4 ´ 4)

Disassembled View

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241R200005

Legend
(1) Oil seal
(2) Adapter housing
E nd O FCallo ut

Disassembly
1. Using a screwdriver, remove the oil seal.

Reassembly
1. Using oil seal installer, install the new oil seal to the
adapter housing.
Oil seal installer : J–36797

RUW37ASH002401
7A4–126 UNIT REPAIR (AW30–40LE)

Extension Housing (4 ´ 2)

Disassembled View

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241R200007

Legend (4) Oil seal

(1) Gasket (5) Dust deflector
(2) Tube (6) Extension housing
(3) Tube packing
E nd O FCallo ut

Disassembly
1. Remove the gasket.
2. Remove the tube.
3. Remove the tube packing.
4. Using a screwdriver, remove the oil seal.
NOTE: The oil seal can be removed without removing
the dust deflector.
5. Rrmove the dust deflector from extension housing.

Reassembly
1. Using oil seal installer, install the new oil seal to the
extension housing.
Oil seal installer : 5–8840–2702–0
NOTE: The oil seal can be installed without removing
the dust deflector. 249L100005
 UNIT REPAIR (AW30–40LE) 7A4–127
2. Install the tube.
3. Install the tube packing.
4. Install the dust deflector.
5. Install the gasket.

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7A4–128 UNIT REPAIR (AW30–40LE)

Main Data and Specifications

General Specifications

Remaks
Model AW30–40LE
Engine 6VE1 (3.5L)
Type Electronic control planetary gear type
3–element 1–stage 2–phase type
(with lock-up mechanism)
Gear ratio 1st 2.804
2nd 1.532
3rd 1.000
4th (O/D) 0.705
Reverse 2.394
Oil used Name BESCO ATF III

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Q'ty (l) 8.7
Torque converter 2100 ± 150 Stall speed (rpm)
Friction element
Forward clutch C–1 5
Direct clutch C–2 4 Number of discs
OD direct clutch C–0 2
Second coast brake B–1 40mm Band width or
Number of discs
Second brake B–2 5
First and reverse brake B–3 6 Number of discs
Overdrive brake B–0 4
Clutch
One-way clutch No.1 F–1 22
Number of
One-way clutch No.2 F–2 28
sprage
OD one-way clutch F–0 24
Planetary gear
Front planetary Sun gear 42
Pinion gear 19
Ring gear 79
Rear planetary Sun gear 33
Pinion gear 23 Number of teeth
Ring gear 79
O/D planetary Sun gear 33
Pinion gear 23
Ring gear 79
 UNIT REPAIR (AW30–40LE) 7A4–129
Torque Specifications

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RTW37ALF002101
7A4–130 UNIT REPAIR (AW30–40LE)
Torque Specifications (Cont'd)
N·m (Ibft)

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RTW37ALF001001
 UNIT REPAIR (AW30–40LE) 7A4–131
Torque Specifications (Cont'd)
N·m (Ibft)

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RTW37ALF000901
7A4–132 UNIT REPAIR (AW30–40LE)

Special Tools
TOOL NO. TOOL NO.
ILLUSTRATION ILLUSTRATION
TOOL NAME TOOL NAME

J–37227 J–29770–A
Holding fixture Oil pressure gauge

J–3289–20 J–25048
Holding fixture base Spring compressor

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J–37236
J–37228 Reaction sleeve puller;
Oil pan seal cutter first and reverse brake

J–37237
J–23327–1 Piston puller; first and
Spring compressor reverse brake

J–37232–2
J–9617 Oil seal installer;
Oil seal installer; oil manual valve shaft seal
pump installer & remover

J–35467
J–37233 Onennway clutch
Spring compressor; OD testing tool; torque
brake piston converter
 UNIT REPAIR (AW30–40LE) 7A4–133

TOOL NO.
ILLUSTRATION
TOOL NAME

J–36797
Oil seal installer;
adapter housing (4 ´ 4)

J–46197
Oil seal installer;
extension housing (4 ´
2)

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7A4–134 UNIT REPAIR (AW30–40LE)

MEMO

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No. TFAW3-WE-0431