AUTOMATIC TRANSAXLE UNIT INSPECTION

PROCEDURE


  1. INSPECT TRANSMISSION OIL CLEANER MAGNET


    1. Examine the particles in the automatic transaxle oil pan sub-assembly.


      1. B001O37

        Collect any steel chips with the removed transmission oil cleaner magnets. Look carefully at the chips and particles in the automatic transaxle oil pan sub-assembly and on the transmission oil cleaner magnets to see the type of wear which might be found in the automatic transaxle assembly.

        Result
        Steel (Magnetic) Brass (Non-magnetic)
        Bearing, gear and plate wear Bushing wear

  2. INSPECT INPUT SHAFT END PLAY


    1. B001OLT

      Using a dial indicator, measure the input shaft end play.

      Standard end play
      0.020 to 1.242 mm (0.000788 to 0.0488 in.)

  3. INSPECT INTERMEDIATE SHAFT END PLAY


    1. B001O76E02
      Text in Illustration
      *a Dimension A

      Clean the contact surfaces of the transaxle case sub-assembly and rear transaxle cover sub-assembly.

    2. As shown in the illustration, place a straightedge on the multiple direct clutch drum and measure the distance between the transaxle case sub-assembly and the straightedge using a vernier caliper (Dimension A).

    3. B001NYVE03
      Text in Illustration
      *a Dimension B

      Using a vernier caliper and a straightedge, measure the distance shown in the illustration (Dimension B).

    4. Calculate the end play value using the following formula:

      End play = Dimension B - Dimension A - Thrust needle roller bearing thickness

      Standard end play
      0.022 to 1.099 mm (0.000867 to 0.0432 in.)

  4. INSPECT PLANETARY SUN GEAR SUB-ASSEMBLY


    1. B001OFA

      Using a caliper gauge, 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.

  5. INSPECT REAR PLANETARY SUN GEAR ASSEMBLY


    1. A01W4FT

      Using a caliper gauge, measure the inside diameter of the bushings 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.

  6. INSPECT UNDERDRIVE PLANETARY GEAR ASSEMBLY


    1. A01W2MP

      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.

  7. INSPECT ONE-WAY CLUTCH ASSEMBLY


    1. B001NMPE05
      Text in Illustration
      *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.

    2. 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 as specified, replace it.

  8. INSPECT NO. 1 BRAKE DISC


    1. A01W2RN

      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 of the No. 1 brake discs is peeled off or discolored, or even if part of the groove is damaged, replace all the No. 1 brake discs.

      • Before assembling the new No. 1 brake discs, soak them in ATF for at least 15 minutes.

      If necessary, replace them.

  9. INSPECT NO. 2 BRAKE DISC


    1. A01VZU7

      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 of the No. 2 brake discs is peeled off or discolored, or even if part of the groove is damaged, replace all the No. 2 brake discs.

      • Before assembling the new No. 2 brake discs, soak them in ATF for at least 15 minutes.

      If necessary, replace them.

  10. INSPECT NO. 3 BRAKE DISC


    1. B001NRR

      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 of the No. 3 brake discs is peeled off or discolored, or even if part of the groove is damaged, replace all the No. 3 brake discs.

      • Before assembling the new No. 3 brake discs, soak them in ATF for at least 15 minutes.

      If necessary, replace them.

  11. INSPECT 2ND BRAKE PISTON RETURN SPRING SUB-ASSEMBLY


    1. B001O42

      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.

  12. INSPECT 1ST AND REVERSE BRAKE RETURN SPRING SUB-ASSEMBLY


    1. B001OO1

      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.

  13. INSPECT NO. 3 BRAKE PISTON RETURN SPRING SUB-ASSEMBLY


    1. A01W2WX

      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.

  14. INSPECT CLEARANCE OF NO. 1 BRAKE PISTON


    1. A01W59Q

      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.

      No. 1 Brake Flange Thickness
      Mark Thickness [mm (in.)]
      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)

  15. INSPECT CLEARANCE OF NO. 2 BRAKE PISTON


    1. A01W3MR

      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
      0.707 to 0.974 mm (0.0278 to 0.0383 in.)

      Tech Tips

      Measure the clearance at 3 points where the No. 2 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. 2 brake flange so that the clearance will be within the specified range.

      No. 2 Brake Flange Thickness
      Mark Thickness [mm (in.)]
      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)

  16. INSPECT CLEARANCE OF NO. 3 BRAKE PISTON


    1. 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 No. 3 brake flange.

      B001OQRE03
      Text in Illustration
      *1 Front Oil Pump Assembly *2 No. 3 Brake Piston
      *3 No. 3 Brake Flange - -
      *a Dimension (A) *b Dimension (B)
      *c Contact Surface of Front Oil Pump Assembly - -

      Tech Tips

      Measure the distance (Dimension(A)) at 3 points where the No. 3 brake flange diameter is approximately 166 mm (6.54 in.) and calculate the average.

    2. Using a vernier caliper and a straightedge, measure the distance shown in the illustration (Dimension (B)).

      Tech Tips

      Measure the distance (Dimension(B)) at 3 points where the No. 3 brake piston diameter is approximately 166 mm (6.54 in.) and calculate the average.

    3. Calculate the clearance using the following formula:

      Clearance = Dimension (B) - Dimension (A)

      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.

    4. Adjust clearance of No. 3 brake piston:


      1. B001NSWE03
        Text in Illustration
        *a Protective Tape

        Using a screwdriver with its tip wrapped with protective tape, remove the snap ring from the front oil pump assembly.

      2. B001OMOE01
        Text in Illustration
        *1 No. 3 Brake Flange

        Remove the No. 3 brake flange from the front oil pump assembly.

      3. 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 No. 3 brake disc.

        B001O4GE03
        Text in Illustration
        *1 Front Oil Pump Assembly *2 No. 3 Brake Piston
        *3 No. 3 Brake Disc - -
        *a Dimension (A) *b Dimension (B)
        *c Contact Surface of Front Oil Pump Assembly - -

        Tech Tips

        Measure the distance (Dimension(A)) at 3 points where the No. 3 brake disc diameter is approximately 166 mm (6.54 in.) and calculate the average.

      4. Using a vernier caliper and a straightedge, measure the distance shown in the illustration (Dimension (B)).

        Tech Tips

        Measure the distance (Dimension(B)) at 3 points where the No. 3 brake piston diameter is approximately 166 mm (6.54 in.) and calculate the average.

      5. Calculate the thickness of the replacement No. 3 brake flange using the following formula:

        Thickness of Replacement No. 3 Brake Flange
        Dimension (B) - Dimension (A) - (0.599 to 0.799 mm (0.0236 to 0.0315 in.))

        Tech Tips

        There are 6 No. 3 brake flanges of different thicknesses.

        No. 3 Brake Flange Thickness
        Mark Thickness (mm (in.))
        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)
      6. B001OMOE01
        Text in Illustration
        *1 No. 3 Brake Flange

        Install the No. 3 brake flange to the front oil pump assembly.

      7. B001O0TE04

        Using a screwdriver with its tip wrapped with protective tape, install the snap ring to the front oil pump assembly.

        Note


        • Confirm that the snap ring is correctly located in the groove of the front oil pump assembly.

        • Make sure that the snap ring ends are positioned as shown in the illustration (A).

  17. INSPECT CLEARANCE OF NO. 1 CLUTCH


    1. A01W3EN

      Install the rear multiple disc clutch assembly onto the rear transaxle cover sub-assembly.

    2. Check that the piston moves when compressed air (200 kPa, 2.0 kgf/cm2, 29 psi) is applied to the oil hole.

    3. B001OKYE02
      Text in Illustration
      *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.

      Standard pack clearance
      0.601 to 0.819 mm (0.0237 to 0.0322 in.)

      If the pack clearance is not as specified, replace the rear multiple disc clutch assembly.

  18. INSPECT CLEARANCE OF NO. 2 CLUTCH


    1. A01W4HB

      Install the rear multiple disc clutch assembly onto the rear transaxle cover sub-assembly.

    2. 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.

      Standard pack clearance
      0.394 to 0.605 mm (0.0155 to 0.0238 in.)

      If the pack clearance is not as specified, replace the rear multiple disc clutch assembly.