Technical Service Information INTRODUCTION TOYOTA A240 The A-240 transaxle is a 4 speed front wheel drive fully automatic transmission with a converter clutch. Trouble-shooting, teardown - assembly, removal and installation is fully covered. This transmission is currently found in the Toyota Corolla models. We thank the Toyota Corporation for the illustrations and information that have made this booklet possible. ROBERT D. CHERRNAY DALE ENGLAND TECHNICAL DIRECTOR FIELD SERVICE CONSULTANT FRANK MIETUS WAYNE COLONNA HOTLINE TECHNICIAN HOTLINE TECHNICIAN ED KRUSE LAY OUT AUTOMATIC TRANSMISSION SERVICE GROUP 9200 SOUTH DADELAND BLVD. SUITE 720 MIAMI, FLORIDA 33156 (305) 661-4161INDEX TROUBLE~SHOOTING ELECTRIC CONTROL .... REMOVAL OF TRANSAXLE ‘TEARDOWN COUNTERSHAFT VALVE BODY ASSEMBLY .... OIFFERENTIALATSG Technical Service Information TROUBLESHOOTING Problem Ponsible cause Remedy Fad dacolored or] Fond contaminated Replace uid smells burnt Torque converter faulty Replace torque converter Transmission faulty Disassemble and inspect transmission Vehicle dots not move | T/M contrl eable out of adjustment ‘Adjust control cable in any forward range ‘Valve body or primary regulator faulty Inspect valve body OF reverse: ‘Transmission faulty Disassemble and inspect [Vericie does not move | Park lock paw faulty Inspect park paw in any range Valve body or primary regulator faulty | Inspect valve body Torque converter faulty Replace torque converter Converter drive plate broken | Replace torque converter O11 Pump intake strainer Blocked Clean strainer | Transmission faulty Disassemble and inspect | transmission Shik lever pouiton TIM control cable ut of adjustment | Agjust contro able incorrect, Manual vale and lever faulty Inspect valve body Transmision faulty Disassembie and inspect transmission Harsh engagement Throttle cable out of adjustment ‘Adjust throttle cable | into any dive range | Valve body or primary regulator faulty | Inspect vave body Accumulator pistons faulty Inspect accumulator pistons Transmission faulty Disassemble and inspect transmission Delayed 1-2, 23 or Throttle cable out of adjustment ‘Adjust throttle cable 3-00 upsshitt, or down | Governor faulty | tnsnect oavernoeTROUBLESHOOTING (Cont'd) Technical Service Information Problem Possible cause Remedy Down-shift occurs too | Throttle cable out of adjustment ‘Adjust throwtle cable 1 ek — tate while | Governor faulty Inspect governor | Valve body faulty Inspect valve body Transmission faulty Disatsemble and inspect No O03, 320r24 Throttle cable out of adjustment ‘Adjust throttle cable kick-down Governor faulty Inspect governor L Valve body faulty Inspect valve body No engine braking Valve body faulty Tnapect valve body Transmission faulty Disassemble and inspect, transmission Vehicle does not TIM control cable out of adjustment ‘Adjust control cable pein Parking lock pawl and rod Inspect lock pawl and rod GENERAL NOTES 1, Troubles occuring with the automatic transmission can be caused by either the engine or the transmis: sion itself. These two areas should be distinctly isolated before proceeding with troubleshooting. 2. Troubleshooting should begin with the simpliest operation, working up in order of difficulty, but first determine whether the trouble lies within the engine or transmission. 3. Proceed with the inspection as follows. (1) Preminary Check Basic check {a) Check oil level. (b} Check throttle cable mark. (c) Check shift cable. (a) Check neutral start switch. (e) Check idle speed. (f) Check tire inflation pressure (See page | FA-3). Repair as necessary. ‘Check engine and torque converter. (2) Stall Test T Repair as necessary. creck ae (3) Time Lag Test Cheek each clutch, brake and gear for wear i Confirm by road test and repair as necessary. ‘Measure line pressure and make basic check of (4) Hydraulic Test ftuid cireuit, Confirm shift point and extent of shock by foad test. Repair as necessary. ‘Check ATM by road test. tb iced hese I Confirm if trouble lies within ATM. If noisy or vibrating, the possible cause could Overhaul transmission be with the compressor, engine, drive shaft, tires, etc. COn-vehicle repairYZ 7 Ads it hot Technical Service Information Ok it hot \M Rubber Boot Cabie Stopper Adjusting Nut Swivel nut ATF INSPECTION 1. CHECK FLUID LEVEL 2. CHECK FLUID CONDITION If the ATF smelles burnt or is black, replace it. 3. REPLACE ATF ADJUSTMENTS ADJUSTMENT OF THROTTLE CABLE 1. DEPRESS ACCELERATOR PEDAL ALL THE WAY AND CHECK THAT THROTTLE VALVE OPENS FULLY If the throttle valve does not open fully, adjust the accele- rator link. 2, FULLY DEPRESS ACCELERATOR 3. LOOSEN ADJUSTMENT NUTS 4, ADJUST THROTTLE CABLE (a) Adjust the cable housing so that the distance between ‘the end of the boot and the stopper on the cable is correct. Distance: 0-1 mm (0 — 0.04 in.) (b) Tighten the adjusting nuts. {c)_ Recheck the adjustments. ADJUSTMENT OF TRANSMISSION CONTROL CABLE (a) Loosen the swivel nut on the lever. {b) Push the manual lever fully toward the right side of the vehicle. (c)_ Return the lever two notches to the NEUTRAL posi- tion, (d) Set the shift lever in “N” range. {e) While holding the lever lightly toward the “R” range side, tighten the swivel nut. ADJUSTMENT OF NEUTRAL START SWITCH If the engine will start with the shift selector in any range other than “N’ or “P” range, adjustment is required. 1. LOOSEN NEUTRAL START SWITCH BOLTS AND SET SHIFT SELECTOR IN “N” RANGE 2, ADJUST NEUTRAL START SWITCH {a) Disconnect the neutral start switch connector. {b) Connect an ohmmeter between the terminals. {c) Adjust the switch to the point where there is con- tinuity between terminals. {d) Connect the neutral start switch connector. 3. TORQUE NEUTRAL START SWITCH BOLTS Torque: 55 kg-cm (48 in.-Ib, 5.4 N-m) 7Technical Service Information ON-VEHICLE REPAIR REMOVAL OF GOVERNOR VALVE REMOVE GOVERNOR COVER AND O-RING ‘A240L REMOVE GOVERNOR BODY WITH THRUST WASHER REMOVE GOVERNOR BODY ADAPTOR INSTALLATION OF GOVERNOR VALVE INSTALL GOVERNOR BODY ADAPTERTechnical Service Information INSTALLATION OF THROTTLE CABLE a INSTALL CABLE IN TRANSMISSION CASE (a) Be sure to push it in all the way. (b) Install the retaining plate and bolt. INSTALL VALVE BODY IF THROTTLE CABLE IS NEW, STAKE STOPPER ON INNER CABLE NOTE: New cable do not have a cable stopper staked. (a) Bend the cable about 200 mm (7.87 in.) in radius. (b) Pull the inner cable lightly until a slight resistance is felt, and hold it. {c)_ Stake the stopper as shown, 0.8 — 1.5 mm (0,031 — 0.059 in.) in width. CONNECT THROTTLE CABLE Connect the cable to the throttle linkage. ADJUST THROTTLE CABLE INSTALL NEUTRAL START SWITCH {a) Install the neutral start switch. (b) Install the manual shift lever. (c)_ Adjust the neutral start switch. (See page AT-4) (d) Connect the transmission control cable. TEST DRIVE VEHICLE 9A2@00 Technical Service Information REMOVAL OF VALVE BODY CLEAN TRANSMISSION EXTERIOR To help prevent contamination, clean the exterior of the transmission. DRAIN TRANSMISSION FLUID Using SST, remove the drain plug and drain the fluid into suitable container, (A130L, A131L) SST 09043-38100 REMOVE OIL PAN AND GASKET CAUTION: Some fluid will remain in the oil pan. Remove all pan bolts, and carefully remove the pan assembly, Discard the gasket. REMOVE OIL STRAINER Remove the three bolts, and the oil strainer. CAUTION: Be careful as some oil will come out with the strainer. REMOVE OIL TUBES Pry up both tube ends with a large screwdriver and re move the tubes. REMOVE MANUAL DETENT SPRING 10Technical Service Information REMOVE VALVE BODY (a) Remove the fourteen bolts. ‘A240 {b) Disconnect the throttle cable. (c) Disconnect the manual valve connecting rod. (A240L) (d) Remove the valve body. REMOVE GOVERNOR APPLY GASKET SX AUTOMATIC TRANSMISSION SERVICE GROUPTechnical Service Information INSTALLATION OF VALVE BODY ROL 22530 INSTALL FOURTEEN BOLTS IN VALVE BODY fash NOTE: Each bolt length (mm) is indicated in the figure. will Pgs Finger tighten the all bolts first. Then tighten them with a xl ~VReL— 20 torque wrench. Torque: 100 kg-cm (7 ft-lb, 10 N-m) 3020 2020 onoos “A2A0L. INSTALL OIL TUBES a i i ° Tap the tubes with a plastic hammer to install them into the positions indicated in the figure, CAUTION: Be careful not to bend or damage the tubes. INSTALL DETENT SPRING NOTE: Each bolt length (mm) is indicated in the figure. (a) Finger tighten the all bolts first. Then tighten them with a torque wrench, Torque: 100 kg-cm (7 ftlb, 10 N-m) (b) Check that the manual vaive lever is in contact with the center of the roller at the tip of the detent spring. INSTALL OIL STRAINER Each bolt length (mm) is indicated in the figure. AUTOMATIC TRANSMISSION SERVICE GROUP 12Technical Service Information ELECTRIC CONTROL (A240L) CIRCUIT Gauge Fuse ® ov oFF Indieator +ie FAVEET T [le > ® ODOFF indicator @_ OD Solenoid (Wire side) {SMW side) (i [5] Fae Indicator lumination © 00 Main saw (SAW sided © water Thremo S/W (S/W side) 13TSG Technical Service Information REMOVAL OF TRANSAXLE ik 2. 3. 10. n, 12, REMOVE NEGATIVE BATTERY TERMINAL REMOVE AIR CLEANER DISCONNECT NEUTRAL START SWITCH CONNECTOR DISCONNECT SOLENOID VALVE CONNECTOR (A240L) DISCONNECT SPEEDOMETER CABLE REMOVE THROTTLE CABLE REMOVE CONTROL CABLE (a) Remove the clip. (b) Remove the retainer. (c) Remove the contro! cable bracket. DISCONNECT OIL COOLER HOSE REMOVE WATER INLET (4A-C engine) RAISE VEHICLE AND DRAIN TRANSAXLE REMOVE ENGINE UNDER COVER REMOVE FRONT AND REAR MOUNTING (a) (b) te) Remove the two dust covers from the member. Remove the four bolts. Remove the front and rear mounting. 14Technical Service Information 13, REMOVE ENGINE MOUNTING CENTER MEMBER (a) Remove the four bolts. (b) Remove the center member. 14. REMOVE DRIVE SHAFT 15, REMOVE STEERING KNUCKLE 16. REMOVE STARTER MOTOR 17, REMOVE ENGINE REAR END PLATE (4A engine 18. REMOVE REAR END PLATE HOLE PLUG (1C engine) 19, REMOVE SIX TORQUE CONVERTER MOUNTING BOLTS (a) Turn the crankshaft to gain access to each bolt. {b) Hold the crankshaft pulley nut with a wrench. {c) Remove the six bolts. 20. REMOVE LH ENGINE MOUNTING (a) Hold the engine and transaxle with two jacks, or a chain block and jack. (b) Remove the mounting set bolts. 21, REMOVE TRANSAXLE MOUNTING BOLTS 22. INSTALL GUIDE PIN IN TORQUE CONVERTER Install the guide pin in one of the torque converter bolt holes. If necessary, a guide pin can be made by cutting off the head of a bolt. 23. PRY ON END OF GUIDE PIN TO BEGIN MOVING TRANSMISSION WITH CONVERTER ‘The guide pin helps keep the converter with the transmis sion. 24, REMOVE TRANSAXLE ASSEMBLY FROM ENGINE 25. REMOVE TORQUE CONVERTER FROM TRANSMISSION 15Technical Service Information DISASSEMBLY OF TRANSMISSION (A240L) COMPONENTS Governor Driven Gear ‘Throttle Cable Oil Fitler Tube Gasket | Thrust Washer Governor Body }@ O-Ring Cover Bracket —@y Governor Cover oe Transaxle Housing Manual ‘Shift Lever Manual Valve ‘Spring (Pq — Oi Gallery Cover 0 sv kserew eso By Accumulator Piston Snap Ring |@0-Ring Second Coast: ET Brake Piston ft we Cover ‘Accumulator Piston @Gasker Cover Tightening torque lo © Nowreusable part 3k: Precoated part age4 ATSG Technical Service Information COMPONENTS (Cont'd)Technical Service Information COMPONENTS (Cont'd) Lock Paw! Shaft | Parking Lock Paw! Pawl Shaft Clamp | ob ot 8 Guide Sleeve cam Guide Parking Lock ‘Sleeve Stopper Plate Parking Manual Valve toacttes | Sut WSoacer | washer © Oi Seat Manual Retaining Soring Vatve Lever Differential Drive Pinion ‘and Output Flange Snap Ring Outer Race Outer Race Inner Race Lock Nut Bearing ; 5 ‘ Md | A are vo a . * f 0} Counter Driven Gear Besring Oil Seat Ring Needle Bearing ikgcem (eI, Nema] : Tightening torque ©: Noneuabe par sy Snap Ring Return Spring 18Technical Service Information SEPARATE BASIC SUBASSEMBLY 1. REMOVE TWO OIL COOLER PIPES 2. REMOVE OIL FILLER GAUGE AND TUBE 3. REMOVE MANUAL SHIFT LEVER 4. REMOVE NEUTRAL START SWITCH REMOVE THROTTLE CABLE RETAINING PLATE 6. REMOVE SOLENOID WIRE RETAINING PLATE 7. REMOVE GOVERNOR BODY (a) Remove the two bolts and cover brackets. (b) Remove the governor cover and O-ring. {c) Remove the governor body with thrust washer. {d) Remove the three bolts and governor body adaptor. (e) Remove the gasket. 19Technical Service Information 8 REMOVE PAN AND GASKET {a) Remove the eighteen bolts. (b) Remove the pan by lifting the transmission case, CAUTION: Do not turn the transmission over as it will contaminate the valve body with the foreign materi the bottom of the pan. (c) Place the transmission on wooden blocks to prevent damage to the pipe. 9, EXAMINE PARTICLES IN PAN My Remove the magnet and use it to collect any steel chips. Look carefully at the chips and particles in the pan and on A the magnet to anticipate what type of wear you will find in the transmission Steel (magnetic)... . bearing, gear and clutch plate wear Brass (non-magnetic) . .. bushing wear 10. TURN TRANSMISSION OVER AND REMOVE OIL STRAINER 11, REMOVE FIVE OIL TUBES Pry up both tube ends with a large screwdriver and remove the five tubes. 12, REMOVE MANUAL DETENT SPRING 20Technical Service Information 13, DISCONNECT SOLENOID 14, REMOVE VALVE BODY (a) Remove the solenoid set bolt. {b) Remove teh thirteen bolts and wire retail (c) Disconnect the throttle cable from the cam. (d) Disconnect manual valve connecting rod from the manual valve lever and remove the valve body. 15, REMOVE THROTTLE CABLE FROM CASE 16. REMOVE SOLENOID WIRE 21Technical Service Information 17. REMOVE GOVERNOR APPLY GASKET 18, REMOVE C, ACCUMULATOR PISTON AND SPRING Using low pressure compressed air (1 kg/em?, 14 psi or 98 kPa) pop out the piston into a rag. Force air into the hole shown and remove the piston and spring. 19. REMOVE ACCUMULATOR PISTON AND SPRINGS (a) Loosen the six bolts one turn at a time until the spring tension is released. (b) Remove the cover and the gasket. (c)_ Remove the piston and spring for C1. (d) Using low-pressure compressed air (1 kg/em?, 14 psi or 98 98 kPa) pop out piston Bs and Ca it Force air into the hole shown and remove the piston, and springs. 20. TURN TRANSMISSION OVER AND MEASURE PISTON STROKE OF SECOND COAST BRAKE (2) Remove the snap ring, {b) Remove the cover. {c)_ Remove the piston and the outer spring. {d) Install the piston without the outer spring, (e) Install the snap ring. (f)_ Firmly push the brake apply rod into the case. At this time, measure the distance between the outside of the snap ring and the tip of the piston rod as shown. Distance: 14.0 — 15.5 mm (0.551 — 0.610 in.) [Actual piston stroke is 1.5 — 3.0 mm (0.059 —0.118in.)} (a) Remove the snap ring and piston, 22Technical Service Information 21, REMOVE SIX BOLTS HOLDING OIL PUMP TO TRANSMISSION CASE 22, PULL OIL PUMP FREE FROM TRANSMISSION CASE WITH SST SST 09350-32011 23, REMOVE OIL PUMP 24. WATCH FOR RACE AND BEARING BEHIND OIL PUMP 2. REMOVE DIRECT CLUTCH 26. REMOVE FORWARD CLUTCH 27. WATCH FOR RACE ara 2328. 29. 30. 31, 32. Technical Service Information REMOVE SECOND COAST BRAKE BAND {a) Push the pin with a small screwdriver and remove it from the bolt hole of the oil pump mounting. (b) Remove the brake band. REMOVE FRONT PLANETRARY RING GEAR WITH BEARING AND RACE WATCH FOR RACE AND BEARING ON RING GEAR REMOVE FRONT PLANETARY GEAR WITH RACE WATCH FOR RACES AND BEARING ON FRONT PLANETARY GEAR 24