AUTOMATIC TRANSMISSION UNIT INSPECTION

PROCEDURE


  1. INSPECT DIRECT CLUTCH DRUM SUB-ASSEMBLY


    1. B001ZRK

      Using a caliper gauge, measure the inside diameter of the direct clutch drum sub-assembly bushing.

      Standard Inside Diameter
      59.515 to 59.540 mm (2.3432 to 2.3440 in.)

      If the inside diameter is not as specified, replace the direct clutch drum sub-assembly.

  2. INSPECT INPUT SHAFT SUB-ASSEMBLY


    1. B001WZC

      Using a caliper gauge, measure the inside diameter of the input shaft sub-assembly bushing.

      Standard Inside Diameter
      20.000 to 20.025 mm (0.7874 to 0.7883 in.)

      If the inside diameter is not as specified, replace the input shaft sub-assembly.

  3. INSPECT FORWARD CLUTCH HUB SUB-ASSEMBLY


    1. B001ZED

      Using a caliper gauge, measure the inside diameter of the forward clutch hub sub-assembly bushing.

      Standard Inside Diameter
      26.037 to 26.062 mm (1.0251 to 1.0260 in.)

      If the inside diameter is not as specified, replace the forward clutch hub sub-assembly.

  4. INSPECT SUN GEAR INPUT DRUM SUB-ASSEMBLY


    1. B001XMK

      Using a caliper gauge, measure the inside diameter of the sun gear input drum sub-assembly bushing.

      Standard Inside Diameter
      35.811 to 35.835 mm (1.4099 to 1.4108 in.)

      If the inside diameter is not as specified, replace the sun gear input drum sub-assembly.

  5. INSPECT FRONT PLANETARY GEAR ASSEMBLY


    1. B001W4F

      Using a caliper gauge, measure the inside diameter of the front planetary gear assembly bushing.

      Standard Inside Diameter
      35.811 to 35.835 mm (1.4099 to 1.4108 in.)

      If the inside diameter is not as specified, replace the front planetary gear assembly.

  6. INSPECT FRONT PLANETARY RING GEAR FLANGE SUB-ASSEMBLY


    1. B001XR3

      Using a caliper gauge, measure the inside diameter of the front planetary ring gear flange sub-assembly bushing.

      Standard Inside Diameter
      54.038 to 54.063 mm (2.1275 to 2.1284 in.)

      If the inside diameter is not as specified, replace the front planetary ring gear flange sub-assembly.

  7. INSPECT REAR PLANETARY RING GEAR FLANGE SUB-ASSEMBLY


    1. B001Z6P

      Using a caliper gauge, measure the inside diameter of the rear planetary ring gear flange sub-assembly bushing.

      Standard Inside Diameter
      32.176 to 32.201 mm (1.2668 to 1.2677 in.)

      If the inside diameter is not as specified, replace the rear planetary ring gear flange sub-assembly.

  8. INSPECT CENTER PLANETARY GEAR ASSEMBLY


    1. B001WUJ

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

      Standard Clearance
      0.12 to 0.68 mm (0.00473 to 0.0267 in.)

      If the clearance is not as specified, replace the center planetary gear assembly.

  9. INSPECT REAR PLANETARY GEAR ASSEMBLY


    1. B001XET

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

      Standard Clearance
      0.2 to 0.6 mm (0.00788 to 0.0236 in.)

      If the clearance is not as specified, replace the rear planetary gear assembly.

    2. B001XB8

      Using a caliper gauge, measure the inside diameter of the rear planetary gear bushing.

      Standard Inside Diameter
      20.000 to 20.025 mm (0.7874 to 0.7883 in.)

      If the inside diameter is not as specified, replace the rear planetary gear assembly.

  10. INSPECT NO. 3 ONE-WAY CLUTCH ASSEMBLY


    1. B001YE1

      Hold the rear planetary ring gear and turn the No. 3 one-way clutch assembly.

      Text in Illustration
      B001XPG Lock
      B001WGT Free

    2. Check that the No. 3 one-way clutch assembly turns freely when turned counterclockwise and locks when turned clockwise.

      If there is a problem with the No. 3 one-way clutch assembly, replace it.

  11. INSPECT INTERMEDIATE SHAFT


    1. B001XOF

      Using a dial indicator, check the intermediate shaft runout.

      Standard Runout
      0.03 mm (0.00118 in.)

      If the runout is more than the standard, replace the intermediate shaft with a new one.

    2. B001ZMAE02

      Using a micrometer, check the outer diameter of the intermediate shaft at each point shown in the illustration.

      Standard Diameter
      A
      32.062 to 32.075 mm (1.2623 to 1.2627 in.)
      B
      25.962 to 25.975 mm (1.0222 to 1.0226 in.)
      C
      19.963 to 19.976 mm (0.7860 to 0.7864 in.)

      If the outer diameter is less than the minimum, replace the intermediate shaft with a new one.

  12. INSPECT FORWARD CLUTCH RETURN SPRING SUB-ASSEMBLY


    1. B00200C

      Using a vernier caliper, measure the free length of the forward clutch return spring sub-assembly including the spring seat.

      Standard Free Length
      26.74 mm (1.053 in.)

      If the free length is more than the standard free length, replace the forward clutch return spring sub-assembly.

  13. INSPECT DIRECT CLUTCH RETURN SPRING SUB-ASSEMBLY


    1. B00200C

      Using a vernier caliper, measure the free length of the direct clutch return spring sub-assembly including the spring seat.

      Standard Free Length
      22.14 mm (0.872 in.)

      If the free length is less than the standard free length, replace the direct clutch return spring sub-assembly.

  14. INSPECT NO. 1 BRAKE PISTON RETURN SPRING SUB-ASSEMBLY


    1. B00200C

      Using a vernier caliper, measure the free length of the No. 1 brake piston return spring sub-assembly including the spring seat.

      Standard Free Length
      16.72 mm (0.658 in.)

      If the free length is less than the standard free length, replace the No. 1 brake piston return spring sub-assembly.

  15. INSPECT NO. 2 BRAKE PISTON RETURN SPRING SUB-ASSEMBLY


    1. B00200C

      Using a vernier caliper, measure the free length of the No. 2 brake piston return spring sub-assembly including the spring seat.

      Standard Free Length
      16.68 mm (0.657 in.)

      If the free length is less than the standard free length, replace the No. 2 brake piston return spring sub-assembly.

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


    1. B001VLY

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

      Standard Free Length
      23.74 mm (0.935 in.)

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

  17. INSPECT NO. 1 CLUTCH DISC (FORWARD CLUTCH DISC)


    1. B001WNR

      Check if the contact surfaces of the No. 1 clutch discs, No. 1 clutch plates and No. 1 clutch flange are worn or burnt.

      If necessary, replace them.

      Note


      • If the lining of any No. 1 clutch disc is peeled or discolored, or even if part of a groove is damaged, replace all the No. 1 clutch discs.

      • Before installing new No. 1 clutch discs, soak them in ATF for at least 15 minutes.

  18. INSPECT NO. 2 CLUTCH DISC (DIRECT CLUTCH DISC)


    1. B001XJ2

      Check if the contact surfaces of the No. 2 clutch discs, No. 2 clutch plates and No. 2 clutch flange are worn or burnt.

      If necessary, replace them.

      Note


      • If the lining of any No. 2 clutch disc is peeled or discolored, or even if part of a groove is damaged, replace all the No. 2 clutch discs.

      • Before installing new No. 2 clutch discs, soak them in ATF for at least 15 minutes.

  19. INSPECT NO. 1 BRAKE DISC


    1. B001Z2Z

      Check if the contact surfaces of the No. 1 brake discs, No. 1 brake plates and No. 1 brake flange are worn or burnt.

      If necessary, replace them.

      Note


      • If the lining of any No. 1 brake disc is peeled or discolored, or even if part of a groove is damaged, replace all the No. 1 brake discs.

      • Before installing new No. 1 brake discs, soak them in ATF for at least 15 minutes.

  20. INSPECT NO. 2 BRAKE DISC


    1. B001Y94

      Check if the contact surfaces of the No. 2 brake discs, No. 2 brake plates and No. 2 brake flanges are worn or burnt.

      If necessary, replace them.

      Note


      • If the lining of any No. 2 brake disc is peeled or discolored, or even if part of a groove is damaged, replace all the No. 2 brake discs.

      • Before installing new No. 2 brake discs, soak them in ATF for at least 15 minutes.

  21. INSPECT NO. 4 BRAKE DISC


    1. B001YCU

      Check if the contact surfaces of the No. 4 brake discs, No. 4 brake plates and No. 4 brake flanges are worn or burnt.

      If necessary, replace them.

      Note


      • If the lining of any No. 4 brake disc is peeled or discolored, or even if part of a groove is damaged, replace all the No. 4 brake discs.

      • Before installing new No. 4 brake discs, soak them in ATF for at least 15 minutes.

  22. INSPECT CLEARANCE OF NO. 1 CLUTCH (FORWARD CLUTCH)


    1. B001XCTE02
      Text in Illustration
      *1 Selected Forward Clutch Flange
      *a Oil Hole

      Using a dial indicator, measure the clearance of the No. 1 clutch at several points while applying compressed air (196 kPa, 2.0 kgf/cm2, 28 psi) to the oil hole as shown in the illustration, and calculate the average.

      Standard Clearance
      0.75 to 1.05 mm (0.0296 to 0.0413 in.)

      If the clearance is not as specified, select and install an appropriate forward clutch flange that will bring the clearance within the specified range.

      Tech Tips

      There are forward clutch flanges of different thicknesses.

      Forward Clutch Flange Thickness
      Part No. Thickness (mm (in.))
      35635-71010 3.0 (0.118)
      35635-71020 3.1 (0.122)
      35635-71030 3.2 (0.126)
      35635-71040 3.3 (0.130)
      35635-71050 3.4 (0.134)
      35635-71060 3.5 (0.138)
      35635-71070 3.6 (0.142)
      35635-71080 3.7 (0.146)
      35635-71090 3.8 (0.150)
      35635-71100 3.9 (0.154)
      35635-71110 4.0 (0.157)
      35635-71120 4.1 (0.161)
      35635-71130 4.2 (0.165)

  23. INSPECT CLEARANCE OF NO. 2 CLUTCH (DIRECT CLUTCH)


    1. B001Z6WE02
      Text in Illustration
      *1 Selected Direct Clutch Flange
      *a Oil Hole

      Using a dial indicator, measure the clearance of the No. 2 clutch at several points while applying compressed air (196 kPa, 2.0 kgf/cm2, 28 psi) to the oil hole as shown in the illustration, and calculate the average.

      Standard Clearance
      0.5 to 0.8 mm (0.0197 to 0.0314 in.)

      If the clearance is not as specified, select and install an appropriate direct clutch flange that will bring the clearance within the specified range.

      Tech Tips

      There are direct clutch flanges of different thicknesses.

      Direct Clutch Flange Thickness
      Part No. Thickness (mm (in.))
      35675-71010 3.0 (0.118)
      35675-71020 3.1 (0.122)
      35675-71030 3.2 (0.126)
      35675-71040 3.3 (0.130)
      35675-71050 3.4 (0.134)
      35675-71060 3.5 (0.138)
      35675-71070 3.6 (0.142)
      35675-71080 3.7 (0.146)
      35675-71090 3.8 (0.150)

  24. INSPECT CLEARANCE OF NO. 1 BRAKE


    1. B001Z33

      Make sure that the No. 1 brake piston moves smoothly when applying and releasing compressed air (392 kPa, 4.0 kgf/cm2, 57 psi).

    2. B001WPHE03
      Text in Illustration
      *1 Selected No. 1 Brake Flange

      Using a feeler gauge, measure the No. 1 brake pack clearance between the No. 1 brake disc and No. 1 brake flange.

      Standard Clearance
      0.4 to 0.7 mm (0.0158 to 0.0275 in.)

      If the clearance is not as specified, select and install an appropriate No. 1 brake flange that will bring the clearance within the specified range.

      No. 1 Brake Flange Thickness
      Mark Thickness (mm (in.))
      0 4.9 (0.193)
      1 5.0 (0.197)
      2 5.1 (0.201)
      3 5.2 (0.205)
      4 5.3 (0.209)
      5 5.4 (0.213)
      6 5.5 (0.217)
      7 5.6 (0.220)
      8 5.7 (0.224)
      A 5.8 (0.228)

  25. INSPECT CLEARANCE OF NO. 2 BRAKE


    1. B001ZFD

      Make sure that the No. 2 brake piston moves smoothly when applying and releasing compressed air (392 kPa, 4.0 kgf/cm2, 57 psi).

    2. B001YTLE03
      Text in Illustration
      *1 Selected No. 2 Brake Flange

      Using a feeler gauge, measure the No. 2 brake pack clearance between the No. 2 brake disc and No. 2 brake flange.

      Standard Clearance
      0.5 to 0.8 mm (0.0197 to 0.0314 in.)

      If the clearance is not as specified, select and install an appropriate No. 2 brake flange that will bring the clearance within the specified range.

      No. 2 Brake Flange Thickness
      Mark Thickness (mm (in.))
      0 2.0 (0.0787)
      1 2.1 (0.0827)
      2 2.2 (0.0866)
      3 2.3 (0.0906)
      4 2.4 (0.0945)
      5 2.5 (0.0984)
      6 2.6 (0.102)
      7 2.7 (0.106)
      8 2.8 (0.110)

  26. INSPECT CLEARANCE OF NO. 4 BRAKE


    1. B001Z22

      Make sure that the 1st and reverse brake piston moves smoothly when applying and releasing compressed air (392 kPa, 4.0 kgf/cm2, 57 psi).

    2. B001XTYE04
      Text in Illustration
      *1 Selected No. 4 Brake Flange

      Using a feeler gauge, measure the No. 4 brake pack clearance between the No. 4 brake disc and No. 4 brake flange.

      Standard Clearance
      0.7 to 1.0 mm (0.0276 to 0.0393 in.)

      If the clearance is not as specified, select and install an appropriate No. 4 brake flange that will bring the clearance within the specified range.

      No. 4 Brake Flange Thickness
      Mark Thickness (mm (in.))
      0 1.80 (0.0709)
      1 1.97 (0.0776)
      3 2.11 (0.0831)
      4 2.25 (0.0886)
      5 2.39 (0.0941)
      7 2.53 (0.0996)
      8 2.67 (0.105)
      10 2.81 (0.111)
      11 2.95 (0.116)
      12 3.09 (0.122)
      14 3.23 (0.127)