AUTOMATIC TRANSMISSION UNIT (for 1KD-FTV) INSPECTION


  1. INSPECT EXTENSION HOUSING SUB-ASSEMBLY


    1. A01BATM

      Using a cylinder gauge, measure the inside diameter of the extension housing bushing.

      Maximum inside diameter
      40.03 mm (1.5760 in.)

      If the inside diameter is greater than the maximum, replace the extension housing.

  2. INSPECT AUTOMATIC TRANSMISSION OIL PAN SUB-ASSEMBLY


    1. A01BER6

      Remove the oil cleaner magnets, and use them to collect steel particles.

      Carefully look at the foreign matter and particles in the pan and on the oil cleaner magnets to anticipate the type of wear you will find in the transmission.

      Steel (magnetic)
      Bearing, gear and clutch plate wear
      Brass (non-magnetic)
      Bushing wear

  3. INSPECT OVERDRIVE BRAKE PISTON


    1. A01BB0CE02

      Place SST and a dial indicator onto the overdrive brake piston.

      SST
      09350-30020   ( 09350-06120 )
    2. A01BBUU

      Measure the stroke while applying and releasing compressed air (392 kPa, 4.0 kgf/cm2, 57 psi).

      Piston stroke
      1.40 to 1.70 mm (0.0551 to 0.0669 in.)

      If the piston stroke is less than the limit, parts may be assembled incorrectly, so check and reassemble them if necessary.

      If the piston stroke is still outside the specified range, select another flange.

      Tech Tips

      There are 7 different thicknesses for the flange.

      Flange thickness
      No. Thickness No. Thickness
      77 3.3 mm (0.130 in.) 81 3.8 mm (0.150 in.)
      78 3.5 mm (0.138 in.) 82 3.9 mm (0.154 in.)
      79 3.6 mm (0.142 in.) 83 4.0 mm (0.157 in.)
      80 3.7 mm (0.146 in.) - -

  4. INSPECT PISTON STROKE OF 2ND COAST BRAKE


    1. A01BA61E02

      Place a mark on the 2nd coast brake piston rod.

    2. Using SST, measure the stroke while applying and releasing compressed air (392 kPa, 4.0 kgf/cm2, 57 psi).

      SST
      09240-00020
      Piston rod stroke
      1.50 to 3.00 mm (0.0591 to 0.1181 in.)

      If the stroke is outside the specified range, replace the piston rod.

      Piston rod length
      78.4 mm (3.087 in.) or
      79.9 mm (3.146 in.)

      If the stroke is still outside the specified range, replace the 2nd coast brake band assembly with a new one.

  5. INSPECT OUTPUT SHAFT


    1. A01BE4F

      Using a dial indicator, measure the end play of the output shaft by hand.

      End play
      0.30 to 1.04 mm (0.0118 to 0.0409 in.)

      If the value is outside the standard range, check for improper installation.

    2. Check that the output shaft rotates smoothly.

  6. INSPECT FRONT PLANETARY RING GEAR SUB-ASSEMBLY


    1. A01BDKA

      Using a dial indicator, measure the inside diameter of the planetary ring gear bushing.

      Maximum inside diameter
      24.02 mm (0.9457 in.)

      If the inside diameter is greater than the maximum, replace the planetary ring gear sub-assembly.

  7. INSPECT PLANETARY PINION GEAR THRUST CLEARANCE


    1. A01BDG6

      Using a feeler gauge, measure the planetary pinion gear thrust clearance.

      Standard clearance
      0.20 to 0.60 mm (0.0079 to 0.0236 in.)
      Maximum clearance
      0.60 mm (0.0236 in.)

      If the clearance is greater than the maximum, replace the planetary gear assembly.

  8. INSPECT PACK CLEARANCE OF 2ND BRAKE


    1. A01BBCB

      Using a feeler gauge, measure the clearance between the snap ring and the flange.

      Standard clearance
      0.62 to 1.98 mm (0.0244 to 0.0780 in.)

      If the clearance is outside the standard, check for improper installation.

  9. INSPECT PACK CLEARANCE OF 1ST AND REVERSE BRAKE


    1. A01BDE3

      Using a feeler gauge, measure the clearance between the plate and the 2nd brake drum.

      Standard clearance
      0.70 to 1.22 mm (0.0276 to 0.0480 in.)

      If the clearance is outside the standard range, select another flange.

      Flange thickness
      No. Thickness No. Thickness
      67 5.4 mm (0.213 in.) 52 4.6 mm (0.181 in.)
      66 5.2 mm (0.205 in.) 53 4.4 mm (0.173 in.)
      50 5.0 mm (0.197 in.) 54 4.2 mm (0.165 in.)
      51 4.8 mm (0.189 in.) 55 4.0 mm (0.157 in.)

  10. INSPECT 1ST AND REVERSE BRAKE CLUTCH DISC


    1. A01BEPDE02

      Check if the sliding surfaces of the disc, the plate and the flange are worn or burnt. If necessary, replace them.

      Tech Tips


      • If the lining of the disc is peeled off or discolored, or even if only a part of the printed numbers is corroded, replace all discs.

      • Before assembling new discs, soak them in ATF for at least 15 minutes.

  11. INSPECT PISTON STROKE OF 1ST AND REVERSE BRAKE


    1. A01BBIL

      Make sure that the No. 2 1st and reverse brake piston move smoothly when applying and releasing compressed air into the transmission case.

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


    1. A01BGSDE02

      Check the return spring free length together with the spring seat.

      Standard free length
      18.39 mm (0.7240 in.)

      If the free length is shorter than the standard free length, replace the 1st and reverse brake return spring sub-assembly.

  13. INSPECT AUTOMATIC TRANSMISSION CASE SUB-ASSEMBLY


    1. A01BB7Z

      Using a cylinder gauge, measure the inside diameter of the automatic transmission case rear bushing.

      Maximum inside diameter
      38.13 mm (1.5012 in.)

      If the inside diameter is greater than the maximum, replace the automatic transmission case sub-assembly.

  14. INSPECT INPUT SHAFT SUB-ASSEMBLY


    1. A01BCN2E02

      Make sure that the input shaft rotates smoothly.

  15. INSPECT INDIVIDUAL PISTON OPERATION INSPECTION


    1. A01BAPCE06

      Check for the sound while applying compressed air into the oil hole indicated in the illustration.

      Tech Tips

      Inspect the overdrive direct clutch with the C-0 accumulator piston hole closed. If there is no sounds from the overdrive direct clutch, disassemble and check the installation conditions of the following parts:


      1. Overdrive direct clutch

      2. Direct clutch

      3. Forward clutch

      4. Overdrive brake

      5. 2nd coast brake

      6. 2nd brake

      7. 1st and reverse brake