AUTOMATIC TRANSMISSION UNIT INSPECTION


  1. INSPECT EXTENSION HOUSING SUB-ASSEMBLY


    1. A003CTI

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

      Maximum inside diameter
      40.02 mm (1.5756 in.)

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

  2. INSPECT AUTOMATIC TRANSMISSION OIL PAN SUB-ASSEMBLY


    1. A003C9I

      Remove the magnets and use them to collect steel particles.

    2. Carefully look at the foreign matter and particles in the pan and on the 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. A003FOVE01

      Place SST and a dial indicator onto the O/D brake piston.

      SST
      09350-30020   ( 09350-06120 )
    2. A003ESP

      Measure the stroke while applying and releasing compressed air (392 to 785 kPa, 4.0 to 8.0 kgf/cm2, 57 to 114 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 have been assembled incorrectly, so check and reassemble again.

      If the piston stroke is outside the standard, 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. A003BJWE01

      Place a mark on the 2nd coast brake piston rod as shown in the illustration.

    2. A003EIAE01

      Using SST, measure the stroke while applying and releasing compressed air (392 to 785 kPa, 4.0 to 8.0 kgf/cm2, 57 to 114 psi).

      SST
      09240-00020
      Piston stroke
      1.5 to 3.0 mm (0.059 to 0.018 in.)

      If the stroke is outside the standard, inspect the brake band.

  5. INSPECT FRONT PLANETARY RING GEAR SUB-ASSEMBLY


    1. A003E9O

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

      Maximum inside diameter
      24.65 mm (0.9705 in.)

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

  6. INSPECT PLANETARY PINION GEAR THRUST CLEARANCE


    1. A003H92

      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
      0.65 mm (0.0256 in.)

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

  7. INSPECT PACK CLEARANCE OF SECOND BRAKE


    1. A003FL9

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

      Clearance
      0.62 to 1.98 mm (0.0244 to 0.0780 in.)

      If the clearance is outside the standard, inspect the discs.

  8. INSPECT PACK CLEARANCE OF FIRST AND REVERSE BRAKE


    1. A003FHK

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

      Clearance
      0.70 to 1.22 mm (0.0276 to 0.048 in.)

      If the clearance is outside the standard, inspect the discs.

      Tech Tips

      There are 8 different thicknesses for the 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.)

  9. INSPECT 1ST AND REVERSE BRAKE CLUTCH DISC


    1. A003E4XE01

      Check if the sliding surfaces of the disc, the plate and 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.

  10. INSPECT PISTON STROKE OF 1ST AND REVERSE BRAKE


    1. A003ARP

      Make sure the 1st & reverse brake pistons move smoothly when applying and releasing the compressed air into the transmission case.

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


    1. A003GO4E01

      Using vernier calipers, measure the return spring free length together with the spring seat.

      Standard free length
      12.9 mm (0.508 in.)

  12. INSPECT AUTOMATIC TRANSMISSION CASE SUB-ASSEMBLY


    1. A003F64

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

      Maximum inside diameter
      38.19 mm(1.5035 in.)

      If the inside diameter is greater than the maximum, replace the transmission case.

  13. INSPECT OUTPUT SHAFT


    1. A003HTS

      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 values are outside the standard, check for an improper installation.

    2. Check that the output shaft rotates smoothly.

  14. INSPECT INPUT SHAFT SUB-ASSEMBLY


    1. A003DYG

      Make sure the input shaft rotates smoothly.

  15. INSPECT INDIVIDUAL PISTON OPERATION INSPECTION


    1. A003AETE04

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

      Tech Tips

      When inspecting the O/D direct clutch, check the C0 accumulator piston hole is closed.

      If there is no noise, disassemble and check the installation condition of the parts.


      1. O/D direct clutch (C1)

      2. Direct clutch (C2)

      3. Forward clutch (C3)

      4. O/D brake (B1)

      5. 2nd coast brake (B2)

      6. 2nd brake (B3)

      7. 1st and reverse brake (B4)