AUTOMATIC TRANSAXLE UNIT INSPECTION

PROCEDURE


  1. INSPECT TRANSMISSION OIL CLEANER MAGNET


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


      1. B004IER

        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. B004L3F

      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. B004L3LC03
      *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. B004KZLC03
      *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. B004NW7

      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. B004I0J

      Using a caliper gauge, 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.

  6. INSPECT UNDERDRIVE PLANETARY GEAR ASSEMBLY


    1. B004L9M

      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 not as specified, replace the underdrive planetary gear assembly.

  7. INSPECT ONE-WAY CLUTCH ASSEMBLY


    1. B004IFHC03
      *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 normally, replace it.

  8. INSPECT NO. 1 BRAKE DISC


    1. B004I9R

      Check if the contact surfaces of the discs, plates and 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.

  9. INSPECT NO. 2 BRAKE DISC


    1. B004IZX

      Check if the contact surfaces of the discs, plates and 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 discs, soak them in ATF for at least 15 minutes.

      If necessary, replace them.

  10. INSPECT NO. 3 BRAKE DISC


    1. B004M2N

      Check if the contact surfaces of the discs, plates and 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 discs, soak them in ATF for at least 15 minutes.

      If necessary, replace them.

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


    1. B004KG0

      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. B004MQ6

      Using a vernier caliper, measure the free length of each spring of the 1st and reverse brake return spring sub-assembly including 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. B004N4H

      Using a vernier caliper, measure the free length of each spring of the No. 3 brake piston return spring sub-assembly including 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


    1. B004N4I

      Using a dial indicator, measure the clearance of the No. 1 brake 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


    1. B004NCQ

      Using a dial indicator, measure the clearance of the No. 2 brake 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


    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.

      B004IBIC01
      *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. B004JMTC01
        *a Protective Tape

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

      2. B004J57C01
        *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.

        B004M8FC01
        *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. B004J57C01
        *1 No. 3 Brake Flange

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

      7. B00700CN07

        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. B004HOO

      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. B004IKYC03
      *a 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. B004KO4

      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.