AUTOMATIC TRANSAXLE UNIT INSPECTION


  1. INSPECT TRANSMISSION OIL CLEANER MAGNET


    1. A01HR33

      Use the removed magnets to collect any steel chips. Examine the chips and particles in the pan and on the magnets to determine what type of wear has occurred in the transaxle:

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

  2. INSPECT INPUT SHAFT SUB-ASSEMBLY


    1. A01HQ8K

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

      End play
      0.012 to 1.250 mm (0.000473 to 0.0492 in.)

  3. INSPECT NO. 2 CLUTCH DISC (for TMH Made)


    1. A01HPGL

      Check if the contact surfaces of the discs, plates and flange are worn or burnt.

      Note


      • If the lining of any disc is peeled off or discolored, or even if part of the groove is damaged, replace all discs.

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

      If necessary, replace them.

  4. INSPECT PLANETARY SUN GEAR SUB-ASSEMBLY


    1. A01HMHQ

      Using a dial indicator, measure the inside diameter of the bushings of the planetary sun gear.

      Standard inside diameter
      25.525 to 25.546 mm (1.0049 to 1.0057 in.)
      Maximum inside diameter
      25.546 mm (1.0057 in.)

      If the inside diameter is greater than the maximum, replace the planetary sun gear.

  5. INSPECT NO. 1 CLUTCH DISC (for TMH Made)


    1. A01HO70

      Check if the contact surfaces of the discs, plates and flange are worn or burnt.

      Note


      • If the lining of any disc is peeled off or discolored, or even if part of the groove is damaged, replace all discs.

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

      If necessary, replace them.

  6. INSPECT NO. 3 BRAKE DISC


    1. A01HQWC

      Check if the contact surfaces of the discs, plates and flanges are worn or burnt.

      Note


      • If the lining of any disc is peeled off or discolored, or even if part of the groove is damaged, replace all discs.

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

      If necessary, replace them.

  7. INSPECT UNDERDRIVE PLANETARY GEAR ASSEMBLY


    1. A01HNPZ

      Using a feeler gauge, measure the clearance between the underdrive planetary gear 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.

  8. INSPECT REAR PLANETARY SUN GEAR ASSEMBLY


    1. A01HOBS

      Using a dial indicator, measure the inside diameter of the bushing of the rear planetary sun gear sub-assembly.

      Standard inside diameter
      25.580 to 25.601 mm (1.0071 to 1.0079 in.)
      Maximum inside diameter
      25.601 mm (1.0079 in.)

      If the inside diameter is greater than the maximum, replace the rear planetary sun gear assembly.

  9. INSPECT NO. 1 BRAKE DISC


    1. A01HQWC

      Check if the contact surfaces of the discs, plates and flange are worn or burnt.

      Note


      • If the lining of any disc is peeled off or discolored, or even if part of the groove is damaged, replace all discs.

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

      If necessary, replace them.

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


    1. A01HMA9

      Using a vernier caliper, measure the free length of the 3 2nd brake piston return springs including the spring seats.

      Standard free length
      23.85 mm (0.939 in.)

      If the free length is shorter than the standard free length, replace the 2nd brake piston return spring.

  11. INSPECT ONE-WAY CLUTCH ASSEMBLY


    1. A01HQZYE05
      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 normally, replace it.

  12. INSPECT PLANETARY GEAR ASSEMBLY


    1. A01HMBNE01

      Using a feeler gauge, measure the clearance between the planetary gear case and each pinion gear at points A and B.

      Standard Clearance
      Point A
      0.23 to 0.59 mm (0.00906 to 0.0232 in.)
      Point B
      0.16 to 0.66 mm (0.00630 to 0.0259 in.)

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

  13. INSPECT NO. 2 BRAKE DISC


    1. A01HO2O

      Check if the contact surfaces of the discs, plates and flange are worn or burnt.

      Note


      • If the lining of any disc is peeled off or discolored, or even if part of the groove is damaged, replace all discs.

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

      If necessary, replace them.

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

    A01HN2A

    1. Using a vernier caliper, measure the free length of the 1st and reverse brake return spring together with the spring seat.

      Standard free length
      15.79 mm (0.621 in.)

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

  15. INSPECT CLEARANCE OF NO. 2 BRAKE


    1. A01HPPU

      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
      0.884 to 1.196 mm (0.0348 to 0.0471 in.)

      Tech Tips

      Measure the clearance at 3 points where the 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.

      Tech Tips

      There are 5 flanges of different thicknesses.

      No. 2 Brake Flange Thickness: mm (in.)
      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)

  16. INSPECT CLEARANCE OF NO. 1 BRAKE


    1. A01HNT2

      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
      0.807 to 0.974 mm (0.0318 to 0.0383 in.)

      Tech Tips

      Measure the clearance at 3 points where the 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 flanges of different thicknesses.

      No. 1 Brake Flange Thickness: mm (in.)
      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)

  17. INSPECT CLEARANCE OF NO. 3 BRAKE


    1. A01HQNWE04
      Text in Illustration
      *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.

    2. 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.

    3. Calculate the clearance value using the following formula:

      Clearance = Dimension B - Dimension A

      Standard clearance
      0.599 to 0.761 mm (0.0236 to 0.0300 in.)

      If the clearance is not as specified, select an appropriate brake flange so that the clearance will be within the specified range.

      Tech Tips

      There are 6 flanges of different thicknesses.

      No. 3 Brake Flange Thickness: mm (in.)
      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)

  18. INSPECT CLEARANCE OF NO. 1 CLUTCH DISC

    A01HP1IE02

    Note

    There are two different types of rear multiple disc clutch assembly. Refer to the illustration and visually inspect the rear multiple disc clutch assembly to determine if it is for TMH Made or for TMMWV Made.

    Tech Tips

    Two different automatic transaxle assembly models manufactured at different factories are available for this vehicle.

    Referring to the introduction section, check the serial number. Confirm the factory at which the automatic transaxle assembly was manufactured according to the following table.

    Serial Number Factory
    2########## for TMH Made
    3########## for TMMWV Made
    Text in Illustration
    *A for TMMWV Made
    *B for TMH Made

    1. for TMH Made:


      1. A01HPKI

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

      2. Using a dial indicator, measure the No. 1 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 No. 1 clutch flange diameter is approximately 152 mm (5.98 in.) and calculate the average.

        Pack Clearance
        0.806 to 0.974 mm (0.0317 to 0.0383 in.)

        If the pack clearance is not as specified, select an appropriate No. 1 clutch flange so that the pack clearance will be within the specified range.

        Tech Tips

        There are 6 No. 1 clutch flanges of different thicknesses.

        No. 1 Clutch Flange Thickness: mm (in.)
        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)

    2. for TMMWV Made:


      1. A01HNX4

        Install the direct multiple disc clutch assembly to 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. A01HQCNE01
        Text in Illustration
        *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.

        Pack Clearance
        0.606 to 0.774 mm (0.0238 to 0.0305 in.)

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

  19. INSPECT CLEARANCE OF NO. 2 CLUTCH DISC

    A01HP1IE02

    Note

    There are two different types of rear multiple disc clutch assembly. Refer to the illustration and visually inspect the rear multiple disc clutch assembly to determine if it is for TMH Made or for TMMWV Made.

    Tech Tips

    Two different automatic transaxle assembly models manufactured at different factories are available for this vehicle.

    Referring to the introduction section, check the serial number. Confirm the factory at which the automatic transaxle assembly was manufactured according to the following table.

    Serial Number Factory
    2########## for TMH Made
    3########## for TMMWV Made
    Text in Illustration
    *A for TMMWV Made
    *B for TMH Made

    1. for TMH Made:


      1. A01HPKI

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

      2. Using a dial indicator, measure the No. 1 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 No. 1 clutch flange diameter is approximately 152 mm (5.98 in.) and calculate the average.

        Pack Clearance
        0.806 to 0.974 mm (0.0317 to 0.0383 in.)

        If the pack clearance is not as specified, select an appropriate No. 1 clutch flange so that the pack clearance will be within the specified range.

        Tech Tips

        There are 6 No. 1 clutch flanges of different thicknesses.

        No. 1 Clutch Flange Thickness: mm (in.)
        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)

    2. for TMMWV Made:


      1. A01HNX4

        Install the direct multiple disc clutch assembly to 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. A01HQCNE01
        Text in Illustration
        *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.

        Pack Clearance
        0.606 to 0.774 mm (0.0238 to 0.0305 in.)

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