AUTOMATIC TRANSAXLE UNIT INSPECTION


  1. INSPECT TRANSMISSION OIL CLEANER MAGNET


    1. A01HXIB

      Use the removed transmission oil cleaner magnets to collect any steel chips. Examine the chips and particles in the automatic transaxle oil pan sub-assembly and on the transmission oil cleaner magnets to determine what type of wear has occurred in the automatic transaxle assembly:

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

  2. INSPECT INPUT SHAFT SUB-ASSEMBLY END PLAY


    1. A01I20A

      Using a dial indicator, measure the input shaft sub-assembly 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. A01HZW1

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

      Note


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

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

      If necessary, replace them.

  4. INSPECT PLANETARY SUN GEAR SUB-ASSEMBLY


    1. A01I17P

      Using a caliper gauge, measure the inside diameter of the bushings of the planetary sun gear sub-assembly.

      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 sub-assembly.

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


    1. A01I08S

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

      Note


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

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

      If necessary, replace them.

  6. INSPECT NO. 3 BRAKE DISC


    1. A01HZ7A

      Check if the contact surfaces of the No. 3 brake discs, No. 3 brake plates and No. 3 brake flanges are worn or burnt.

      Note


      • If the lining of any No. 3 brake disc is peeled off or discolored, or even if part of the groove is damaged, replace all No. 3 brake discs.

      • Before assembling new No. 3 brake discs, soak them in ATF for at least 15 minutes.

      If necessary, replace them.

  7. INSPECT UNDERDRIVE PLANETARY GEAR ASSEMBLY


    1. A01I0L8

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

  8. INSPECT REAR PLANETARY SUN GEAR ASSEMBLY


    1. A01I08A

      Using a caliper gauge, measure the inside diameter of the bushing of the rear planetary sun gear 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. A01HZ7A

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

      Note


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

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

      If necessary, replace them.

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


    1. A01I154

      Using a vernier caliper, measure the free length of the 3 2nd brake piston return spring sub-assemblies 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 sub-assembly.

  11. INSPECT ONE-WAY CLUTCH ASSEMBLY


    1. A01HZ0BE05
      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 FRONT PLANETARY GEAR ASSEMBLY


    1. A01I1COE01

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

  13. INSPECT NO. 2 BRAKE DISC


    1. A01I0BA

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

      Note


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

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

      If necessary, replace them.

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

    A01I1UO

    1. 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
      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 sub-assembly.

  15. INSPECT CLEARANCE OF NO. 2 BRAKE


    1. A01HZ0AE01
      Text in Illustration
      *1 No. 2 Brake Piston
      *a Clearance

      Apply compressed air to the oil pressure supply hole shown in the illustration, and check the operation of the No. 2 brake piston.

    2. Set a dial indicator as shown in the illustration.

    3. 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.

      • There are 5 No. 2 brake 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

    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

    1. A01I0GVE01
      Text in Illustration
      *1 No. 1 Brake Piston
      *a Clearance

      Apply compressed air to the oil pressure supply hole shown in the illustration, and check the operation of the No. 2 brake piston.

    2. Set a dial indicator as shown in the illustration.

    3. 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.

      • There are 7 No. 1 brake flanges of different thicknesses (for TMH Made).

      • There are 6 No. 1 brake flanges of different thicknesses (for TMMWV Made).

      No. 1 Brake Flange Thickness: mm (in.) (for TMH Made)
      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)
      36 3.6 (0.142)
      No. 1 Brake Flange Thickness: mm (in.) (for TMMWV Made)
      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

    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

    1. A01HXHTE07
      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 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, select an appropriate No. 3 brake flange so that the clearance will be within the specified range.

      Tech Tips

      There are 8 No. 3 brake flanges of different thicknesses (for TMH Made).

      There are 6 No. 3 brake flanges of different thicknesses (for TMMWV Made).

      No. 3 Brake Flange Thickness: mm (in.) (for TMH Made)
      Mark Thickness
      38 3.8 (0.150)
      39 3.9 (0.154)
      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)
      45 4.5 (0.177)
      No. 3 Brake Flange Thickness: mm (in.) (for TMMWV Made)
      Mark Thickness
      38 3.8 (0.150)
      39 3.9 (0.154)
      40 4.0 (0.157)
      41 4.1 (0.161)
      42 4.2 (0.165)
      43 4.3 (0.169)

  18. INSPECT CLEARANCE OF NO. 1 CLUTCH DISC

    A01I21EE02

    Note

    There are two different types of direct multiple disc clutch assembly. Refer to the illustration and visually inspect the direct 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. A01I026

        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).

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

        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.

          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.

        • 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. A01HZXW

        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. A01HYTCE01
        Text in Illustration
        *a Feeler Gauge

        Using a feeler gauge, measure the No. 1 clutch pack clearance.

        Pack Clearance
        0.606 to 0.774 mm (0.0239 to 0.0305 in.)

        Tech Tips

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

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

  19. INSPECT CLEARANCE OF NO. 2 CLUTCH DISC

    A01I21EE02

    Note

    There are two different types of direct multiple disc clutch assembly. Refer to the illustration and visually inspect the direct 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. A01I0J8

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

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

        Pack Clearance
        0.544 to 0.744 mm (0.0214 to 0.0293 in.)

        Tech Tips


        • Measure the clearance 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.

          If the pack clearance is not as specified, select an appropriate No. 2 clutch flange so that the pack clearance will be within the specified range.

        • There are 6 No. 2 clutch flanges of different thicknesses.

        No. 2 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. A01I02R

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

        Pack Clearance
        0.544 to 0.744 mm (0.0214 to 0.0293 in.)

        Tech Tips

        Measure the clearance 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.

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