AUTOMATIC TRANSAXLE UNIT INSPECTION

PROCEDURE


  1. INSPECT TRANSMISSION OIL CLEANER MAGNET

    A004Q31

    1. Examine the particles in the oil pan.


      1. Use the removed magnets to collect any steel chips. Look carefully at the chips and particles in the pan and on the magnet to anticipate what type of wear you will find in the transaxle.

        Steel (magnetic): bearing, gear and plate wear

        Brass (non-magnetic): bush wear

  2. INSPECT INPUT SHAFT SUB-ASSEMBLY

    A004MN7

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

      Standard end play
      0.012 to 1.250 mm (0.000473 to 0.0492 in.)

  3. INSPECT NO. 2 CLUTCH DISC

    A004PNM

    1. 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 the discs.

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

      If necessary, replace the discs, plates and flange.

  4. INSPECT PLANETARY SUN GEAR SUB-ASSEMBLY

    A004PJU

    1. 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 (1.00 to 1.01 in.)
      Maximum inside diameter
      25.546 mm (1.01 in.)

      If the inside diameter is more than the maximum, replace the planetary sun gear sub-assembly.

  5. INSPECT NO. 1 CLUTCH DISC

    A004OIQ

    1. 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 the discs.

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

      If necessary, replace the discs, plates and flange.

  6. INSPECT NO. 3 BRAKE DISC

    A004RTO

    1. 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 the discs.

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

      If necessary, replace the discs, plates and flange.

  7. INSPECT UNDERDRIVE PLANETARY GEAR ASSEMBLY

    A004OV4

    1. 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 more than the standard, replace the underdrive planetary gear assembly.

  8. INSPECT REAR PLANETARY SUN GEAR ASSEMBLY

    A004OBW

    1. 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 (1.007 to 1.008 in.)
      Maximum inside diameter
      25.601 mm (1.008 in.)

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

  9. INSPECT NO. 1 BRAKE DISC

    A004RTO

    1. 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 the discs.

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

      If necessary, replace the discs, plates and flange.

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

    A004OOM

    1. 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 less than the standard, replace the 2nd brake piston return spring sub-assembly.

  11. INSPECT ONE-WAY CLUTCH ASSEMBLY

    A004Q7ME02
    *1 Free
    *2 Lock

    1. 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.

  12. INSPECT PLANETARY GEAR ASSEMBLY

    A004QTYE07

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

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

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

  13. INSPECT NO. 2 BRAKE DISC

    A004TY4

    1. 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 the discs.

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

      If necessary, replace the discs, plates and flange.

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

    A004S83

    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 less than the standard, replace the 1st and reverse brake return spring.

  15. INSPECT PISTON STROKE OF NO. 2 BRAKE

    A004T17

    1. Using a dial indicator, measure the piston stroke of the No. 2 brake while applying compressed air (200 kPa, 2.0 kgf/cm2, 29 psi).

      Standard stroke
      0.884 to 1.196 mm (0.0348 to 0.0471 in.)

      Tech Tips

      Measure the stroke at 3 points where the brake piston diameter is approximately 140 mm (5.51 in.) and calculate the average.

      If the stroke is not as specified, replace the No. 2 brake flange with one of a different thickness so that the stroke is within the specified range.

      Tech Tips

      There are 5 flanges of different thicknesses.

      Flange Thickness
      Mark Thickness
      40 4.0 mm (0.157 in.)
      41 4.1 mm (0.161 in.)
      42 4.2 mm (0.165 in.)
      43 4.3 mm (0.169 in.)
      44 4.4 mm (0.173 in.)

  16. INSPECT PISTON STROKE OF NO. 1 BRAKE


    1. A004PVP

      Using a dial indicator, measure the piston stroke of the No. 1 brake while applying compressed air (200 kPa, 2.0 kgf/cm2, 29 psi).

      Standard stroke
      0.807 to 0.974 mm (0.0318 to 0.0383 in.)

      Tech Tips

      Measure the stroke at 3 points where the brake piston diameter is approximately 140 mm (5.51 in.) and calculate the average.

      If the stroke is not as specified, replace the No. 2 brake flange with one of a different thickness so that the stroke is within the specified range.

      Tech Tips

      There are 7 flanges of different thicknesses.

      Flange Thickness
      Mark Thickness
      30 3.0 mm (0.118 in.)
      31 3.1 mm (0.122 in.)
      32 3.2 mm (0.126 in.)
      33 3.3 mm (0.130 in.)
      34 3.4 mm (0.134 in.)
      35 3.5 mm (0.138 in.)
      36 3.6 mm (0.142 in.)

  17. INSPECT CLEARANCE OF NO. 3 BRAKE

    A004Q6SE02
    Text in Illustration
    *1 Front Oil Pump Assembly
    *2 No. 3 Brake Piston
    *a Dimension A
    *b Dimension B

    1. Using a vernier caliper and straightedge, measure the distance shown in the illustration (dimension A) while a load of 500 N (51 kgf, 112 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 straightedge, measure the distance from the contact surface of the front oil pump to the end of the No. 3 brake piston shown in the illustration (dimension B).

      Tech Tips

      Measure 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 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, replace the No. 2 brake flange with one of a different thickness so that the clearance is within the specified range.

      Tech Tips

      There are 8 flanges of different thicknesses.

      Flange Thickness
      Mark Thickness
      38 3.80 mm (0.150 in.)
      39 3.90 mm (0.154 in.)
      40 4.00 mm (0.157 in.)
      41 4.10 mm (0.161 in.)
      42 4.20 mm (0.165 in.)
      43 4.30 mm (0.169 in.)
      44 4.40 mm (0.173 in.)
      45 4.50 mm (0.177 in.)

  18. INSPECT PISTON STROKE OF NO. 1 CLUTCH DISC

    A004SJ7

    1. Install the direct multiple disc clutch to the rear transaxle cover.

    2. Using a dial indicator, measure the piston stroke of the No. 1 clutch while applying and releasing compressed air (200 kPa, 2.0 kgf/cm2, 29 psi).

      Tech Tips

      Measure the stroke at 3 points where the flange diameter is approximately 152 mm (5.98 in.) and calculate the average.

      Standard stroke
      0.806 to 0.974 mm (0.0318 to 0.0383 in.)

      If the stroke is not as specified, replace the No. 2 brake flange with one of a different thickness so that the stroke is within the specified range.

      Tech Tips

      There are 6 flanges of different thicknesses.

      Flange Thickness
      Mark Thickness
      30 3.0 mm (0.118 in.)
      31 3.1 mm (0.122 in.)
      32 3.2 mm (0.126 in.)
      33 3.3 mm (0.130 in.)
      34 3.4 mm (0.134 in.)
      35 3.5 mm (0.138 in.)

  19. INSPECT PISTON STROKE OF NO. 2 CLUTCH DISC

    A004TXD

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

    2. Using a dial indicator, measure the piston stroke of the No. 2 clutch while applying and releasing compressed air (200 kPa, 2.0 kgf/cm2, 29 psi).

      Tech Tips

      Measure the stroke 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 stroke
      0.544 to 0.744 mm (0.0214 to 0.0293 in.)

      If the stroke is not as specified, replace the No. 2 brake flange with one of a different thickness so that the stroke is within the specified range.

      Tech Tips

      There are 6 flanges of different thicknesses.

      Flange Thickness
      Mark Thickness
      30 3.0 mm (0.118 in.)
      31 3.1 mm (0.122 in.)
      32 3.2 mm (0.126 in.)
      33 3.3 mm (0.130 in.)
      34 3.4 mm (0.134 in.)
      35 3.5 mm (0.138 in.)