INSPECT TRANSMISSION OIL CLEANER MAGNET
Use the removed transmission oil cleaner magnets to collect any steel chips. Examine the chips and particles in the automatic transaxle oil pan sub-assembly and on the transmission oil cleaner magnets to determine what type of wear has occurred in the automatic transaxle assembly:
Result |
---|
Steel (magnetic) |
Bearing, gear and plate wear |
Brass (non-magnetic) |
Bushing wear |
INSPECT INPUT SHAFT SUB-ASSEMBLY
Using a dial indicator, measure the input shaft sub-assembly end play.
End play |
---|
0.020 to 1.242 mm (0.000787 to 0.0489 in.) |
INSPECT PLANETARY SUN GEAR SUB-ASSEMBLY
Using a dial indicator, measure the inside diameter of the bushings of the planetary sun gear sub-assembly.
Standard inside diameter |
---|
25.525 to 25.546 mm (1.00492 to 1.00575 in.) |
Maximum inside diameter |
---|
25.546 mm (1.00575 in.) |
If the inside diameter is greater than the maximum, replace the planetary sun gear sub-assembly.
INSPECT NO. 3 BRAKE DISC
Check if the contact surfaces of the No. 3 brake discs, No. 3 brake plates and No. 3 brake flanges are worn or burnt.
Note
If the lining of any No. 3 brake disc is peeled off or discolored, or even if part of the groove is damaged, replace all No. 3 brake discs.
Before assembling new No. 3 brake discs, soak them in ATF for at least 15 minutes.
If necessary, replace them.
INSPECT UNDERDRIVE PLANETARY GEAR ASSEMBLY
Using a feeler gauge, measure the clearance between the underdrive planetary gear assembly and the pinion gear at 4 points.
Standard clearance |
---|
0.18 to 0.54 mm (0.00709 to 0.0213 in.) |
If the clearance is greater than the standard clearance, replace the underdrive planetary gear assembly.
INSPECT REAR PLANETARY SUN GEAR ASSEMBLY
Using a dial indicator, measure the inside diameter of the bushing of the rear planetary sun gear assembly.
Standard inside diameter |
---|
25.580 to 25.601 mm (1.00708 to 1.00791 in.) |
Maximum inside diameter |
---|
25.601 mm (1.00791 in.) |
If the inside diameter is greater than the maximum, replace the rear planetary sun gear assembly.
INSPECT NO. 1 BRAKE DISC
Check if the contact surfaces of the No. 1 brake discs, No. 1 brake plates and No. 1 brake flange are worn or burnt.
Note
If the lining of any No. 1 brake disc is peeled off or discolored, or even if part of the groove is damaged, replace all No. 1 brake discs.
Before assembling new No. 1 brake discs, soak them in ATF for at least 15 minutes.
If necessary, replace them.
INSPECT 2ND BRAKE PISTON RETURN SPRING SUB-ASSEMBLY
Using a vernier caliper, measure the free length of the 3 2nd brake piston return spring sub-assemblies including the spring seats.
Standard free length |
---|
23.26 mm (0.916 in.) |
If the free length is shorter than the standard free length, replace the 2nd brake piston return spring sub-assembly.
INSPECT ONE-WAY CLUTCH ASSEMBLY
*1 | Planetary Ring Gear |
*2 | One-way Clutch Assembly |
*a | Free |
*b | Lock |
Temporarily install the one-way clutch assembly to the planetary ring gear.
Make sure that the one-way clutch assembly turns freely counterclockwise and locks when turned clockwise.
If the one-way clutch assembly does not operate normally, replace it.
INSPECT NO. 2 BRAKE DISC
Check if the contact surfaces of the No. 2 brake discs, No. 2 brake plates and No. 2 brake flange are worn or burnt.
Note
If the lining of any No. 2 brake disc is peeled off or discolored, or even if part of the groove is damaged, replace all No. 2 brake discs.
Before assembling new No. 2 brake discs, soak them in ATF for at least 15 minutes.
If necessary, replace them.
INSPECT 1ST AND REVERSE BRAKE RETURN SPRING SUB-ASSEMBLY
Using a vernier caliper, measure the free length of the 1st and reverse brake return spring sub-assembly together with the spring seat.
Standard free length |
---|
15.79 mm (0.622 in.) |
If the free length is shorter than the standard free length, replace the 1st and reverse brake return spring sub-assembly.
INSPECT CLEARANCE OF NO. 2 BRAKE PISTON
Using a dial indicator, measure the clearance of the No. 2 brake piston while applying compressed air (200 kPa, 2.0 kgf/cm2, 29 psi).
Standard clearance |
---|
0.884 to 1.196 mm (0.0348 to 0.0471 in.) |
Tech Tips
Measure the clearance at 3 points where the piston diameter is approximately 140 mm (5.51 in.) and calculate the average.
If the clearance is not as specified, select an appropriate No. 2 brake flange so that the clearance will be within the specified range.
Tech Tips
There are 5 No. 2 brake flanges of different thicknesses.
Mark | Thickness |
---|---|
40 | 4.0 (0.157) |
41 | 4.1 (0.161) |
42 | 4.2 (0.165) |
43 | 4.3 (0.169) |
44 | 4.4 (0.173) |
INSPECT CLEARANCE OF NO. 1 BRAKE PISTON
Using a dial indicator, measure the clearance of the No. 1 brake piston while applying compressed air (200 kPa, 2.0 kgf/cm2, 29 psi).
Standard clearance |
---|
0.601 to 0.819 mm (0.0237 to 0.0322 in.) |
Tech Tips
Measure the clearance at 3 points where the No. 1 brake piston diameter is approximately 140 mm (5.51 in.) and calculate the average.
If the clearance is not as specified, select an appropriate No. 1 brake flange so that the clearance will be within the specified range.
Tech Tips
There are 6 No. 1 brake flanges of different thicknesses.
Mark | Thickness |
---|---|
30 | 3.0 (0.118) |
31 | 3.1 (0.122) |
32 | 3.2 (0.126) |
33 | 3.3 (0.130) |
34 | 3.4 (0.134) |
35 | 3.5 (0.138) |
INSPECT NO. 3 BRAKE PISTON RETURN SPRING SUB-ASSEMBLY
Using a vernier caliper, measure the free length of the No. 3 brake piston return spring sub-assembly together with the spring seat.
Standard free length |
---|
9.15 mm (0.360 in.) |
If the free length is shorter than the standard free length, replace the No. 3 brake piston return spring sub-assembly.
INSPECT CLEARANCE OF NO. 3 BRAKE PISTON
*1 | Front Oil Pump Assembly |
*2 | No. 3 Brake Piston |
*a | Dimension A |
*b | Dimension B |
*c | Contact Surface of Front Oil Pump Assembly |
Using a vernier caliper and a straightedge, measure the distance shown in the illustration (Dimension A) while a load of 500 N (51 kgf, 112.4 lbf) is being applied to the flange.
Tech Tips
Measure dimension A at 3 points where the flange diameter is approximately 166 mm (6.54 in.) and calculate the average.
Using a vernier caliper and a straightedge, measure the distance shown in the illustration (Dimension B).
Tech Tips
Measure dimension B at 3 points where the No. 3 brake diameter is approximately 166 mm (6.54 in.) and calculate the average.
Calculate the clearance value using the following formula:
Clearance = Dimension B - Dimension A - Flange Thickness
Standard clearance |
---|
0.599 to 0.799 mm (0.0236 to 0.0315 in.) |
If the clearance is not as specified, select an appropriate No. 3 brake flange so that the clearance will be within the specified range.
Tech Tips
There are 6 No. 3 brake flanges of different thicknesses.
Mark | Thickness |
---|---|
38 | 3.80 (0.150) |
39 | 3.90 (0.154) |
40 | 4.00 (0.157) |
41 | 4.10 (0.161) |
42 | 4.20 (0.165) |
43 | 4.30 (0.169) |
INSPECT CLEARANCE OF NO. 1 CLUTCH DISC
Install the direct multiple disc clutch assembly onto the rear transaxle cover sub-assembly.
Check that the piston moves when compressed air (200 kPa, 2.0 kgf/cm2, 29 psi) is applied to the oil hole.
*1 | Feeler Gauge |
Using a feeler gauge, measure the No. 1 clutch pack clearance.
Tech Tips
Measure the clearance at 3 points where the flange diameter is approximately 152 mm (5.98 in.) and calculate the average.
Pack clearance |
---|
0.601 to 0.819 mm (0.0237 to 0.0322 in.) |
If the pack clearance is not as specified, replace the direct multiple disc clutch assembly.
INSPECT CLEARANCE OF NO. 2 CLUTCH DISC
Install the direct multiple disc clutch assembly onto the rear transaxle cover sub-assembly.
Using a dial indicator, measure the No. 2 clutch pack clearance while applying and releasing compressed air (200 kPa, 2.0 kgf/cm2, 29 psi).
Tech Tips
Measure the clearance at 3 points where the diameter of the No. 2 direct multiple clutch piston is approximately 152 mm (5.98 in.) and calculate the average.
Pack clearance |
---|
0.394 to 0.605 mm (0.0155 to 0.0238 in.) |
If the pack clearance is not as specified, replace the direct multiple disc clutch assembly.