AUTOMATIC TRANSMISSION UNIT INSPECTION


  1. INSPECT AUTOMATIC TRANSMISSION OIL PAN SUB-ASSEMBLY


    1. A015BO5E01

      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

  2. INSPECT NO. 2 1-WAY CLUTCH ASSEMBLY


    1. A0156H7E03

      Hold the reverse clutch hub and turn the 1-way clutch assembly.

    2. Check that the 1-way clutch turns freely clockwise and locks when turned counterclockwise.

  3. INSPECT REAR CLUTCH DISC


    1. A015BZG

      Replace all discs if one of the following problems is present: 1) a disc, plate or flange is worn or burnt, 2) the lining of a disc is peeled off or discolored, or 3) the grooves or printed numbers have even a little bit of damage.

      Note

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

  4. INSPECT REVERSE CLUTCH HUB SUB-ASSEMBLY


    1. A015BPRE01

      Using a dial indicator, measure the inside diameter of the reverse clutch hub bush.

      Standard inside diameter
      35.812 to 35.837 mm (1.410 to 1.411 in.)
      Maximum inside diameter
      35.887 mm (1.413 in.)

      • If the inside diameter is more than the maximum, replace the reverse clutch hub.

  5. INSPECT FORWARD CLUTCH HUB SUB-ASSEMBLY


    1. A0156L5E01

      Using a dial indicator, measure the inside diameter of the forward clutch hub bush.

      Standard inside diameter
      26.037 to 26.062 mm (1.025 to 1.026 in.)
      Maximum inside diameter
      26.112 mm (1.028 in.)

      • If the inside diameter is more than the maximum, replace the forward clutch hub.

  6. INSPECT FORWARD MULTIPLE DISC CLUTCH DISC


    1. A015BDS

      Replace all discs if one of the following problems is present: 1) a disc, plate or flange is worn or burnt, 2) the lining of a disc is peeled off or discolored, or 3) the grooves or printed numbers have even a little bit of damage.

      Note

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

  7. INSPECT FORWARD CLUTCH RETURN SPRING SUB-ASSEMBLY


    1. A015D8P

      Using a vernier caliper, measure the free length of the spring together with the spring seat.

      Standard free length
      26.74 mm (1.05 in.)

  8. INSPECT DIRECT CLUTCH DISC


    1. A01559G

      Replace all discs if one of the following problems is present: 1) a disc, plate or flange is worn or burnt, 2) the lining of a disc is peeled off or discolored, or 3) the grooves or printed numbers have even a little bit of damage.

      Note

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

  9. INSPECT REVERSE CLUTCH RETURN SPRING SUB-ASSEMBLY


    1. A0159EG

      Using a vernier caliper, measure the free length of the spring together with the spring seat.

      Standard free length
      21.04 mm (0.828 in.)

  10. INSPECT DIRECT CLUTCH RETURN SPRING SUB-ASSEMBLY


    1. A015598

      Using a vernier caliper, measure the free length of the spring together with the spring seat.

      Standard free length
      19.51 mm (0.768 in.)

  11. INSPECT NO. 3 BRAKE DISC


    1. A015CHJ

      Replace all discs if one of the following problems is present: 1) a disc, plate or flange is worn or burnt, 2) the lining of a disc is peeled off or discolored, or 3) the grooves or printed numbers have even a little bit of damage.

      Note

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

  12. INSPECT NO. 3 BRAKE PISTON RETURN SPRING SUB-ASSEMBLY


    1. A0156NV

      Using a vernier caliper, measure the free length of the spring together with the spring seat.

      Standard free length
      15.72 mm (0.619 in.)

  13. INSPECT FRONT PLANETARY GEAR ASSEMBLY


    1. A015BGME01

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

      Standard clearance
      0.2 to 0.6 mm (0.00787 to 0.0236 in.)
      Maximum clearance
      0.65 mm (0.0256 in.)

      • If the clearance is more than the maximum, replace the front planetary gear assembly.

    2. A0156NGE01

      Using a cylinder gauge, measure the inside diameter of the front planetary gear bush.

      Maximum inside diameter
      57.48 mm (2.26 in.)

      • If the inside diameter is more than the maximum, replace the front planetary gear.

  14. INSPECT 1-WAY CLUTCH ASSEMBLY

    A015575E03

    1. Install the 1-way clutch to the 1-way clutch inner race.

    2. Hold the 1-way clutch inner race and turn the 1-way clutch assembly. Check that the 1-way clutch turns freely counterclockwise and locks when turned clockwise.

    3. Remove the 1-way clutch from the 1-way clutch inner race.

  15. INSPECT NO. 1 BRAKE DISC


    1. A015BL7

      Replace all discs if one of the following problems is present: 1) a disc, plate or flange is worn or burnt, 2) the lining of a disc is peeled off or discolored, or 3) the grooves or printed numbers have even a little bit of damage.

      Note

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

  16. INSPECT BRAKE PISTON RETURN SPRING SUB-ASSEMBLY


    1. A0159MK

      Using a vernier caliper, measure the free length of the spring together with the spring seat.

      Standard free length
      17.05 mm (0.671 in.)

  17. INSPECT NO. 2 BRAKE DISC


    1. A0155D2

      Replace all discs if one of the following problems is present: 1) a disc, plate or flange is worn or burnt, 2) the lining of a disc is peeled off or discolored, or 3) the grooves or printed numbers have even a little bit of damage.

      Note

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

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


    1. A01586X

      Using a vernier caliper, measure the free length of the spring together with the spring seat.

      Standard free length
      17.45 mm (0.687 in.)

  19. INSPECT CENTER PLANETARY GEAR ASSEMBLY

    A0156CSE01

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

      Standard clearance
      0.12 to 0.68 mm (0.00472 to 0.0268 in.)
      Maximum clearance
      0.73 mm (0.0287 in.)

      • If the clearance is more than the maximum, replace the center planetary gear assembly.

  20. INSPECT NO. 3 1-WAY CLUTCH ASSEMBLY


    1. A015BJDE03

      Hold the rear planetary ring gear flange and turn the 1-way clutch. Check that the 1-way clutch turns freely counterclockwise and locks when turned clockwise.

  21. INSPECT REAR PLANETARY RING GEAR FLANGE SUB-ASSEMBLY

    A0156R2E01

    1. Using a dial indicator, measure the inside diameter of the rear planetary ring gear bush.

      Standard inside diameter
      32.176 to 32.201 (1.267 to 1.268 in.)
      Maximum inside diameter
      32.251 mm (1.270 in.)

      • If the inside diameter is more than the maximum, replace the rear planetary ring gear.

  22. INSPECT INTERMEDIATE SHAFT


    1. A015CTUE04

      Using a dial indicator, measure the intermediate shaft runout.

      Standard runout
      0.03 mm (0.00118 in.)
      Maximum runout
      0.08 mm (0.00315 in.)

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

    2. A01560OE02

      Using a micrometer, measure the diameter of the intermediate shaft at the positions shown in the diagram.

      Standard diameter
      A, B
      25.962 to 25.975 mm (1.022 to 1.023 in.)
      C, D
      32.062 to 32.075 mm (1.262 to 1.263 in.)
      Minimum diameter
      A, B
      25.912 mm (1.02 in.)
      C, D
      32.012 mm (1.26 in.)

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

  23. INSPECT NO. 4 BRAKE DISC


    1. A0159PE

      Replace all discs if one of the following problems is present: 1) a disc, plate or flange is worn or burnt, 2) the lining of a disc is peeled off or discolored, or 3) the grooves or printed numbers have even a little bit of damage.

      Note

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

  24. INSPECT REAR PLANETARY GEAR ASSEMBLY


    1. A0156W8E01

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

      Standard clearance
      0.2 to 0.6 mm (0.00787 to 0.0236 in.)
      Maximum clearance
      0.65 mm (0.0256 in.)

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

    2. A0155TEE01

      Using a dial indicator, measure the inside diameter of the rear planetary gear bush.

      Maximum inside diameter
      20.075 mm (0.790 in.)

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

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


    1. A0155P0

      Using a vernier caliper, measure the free length of the spring together with the spring seat.

      Standard free length
      23.74 mm (0.935 in.)

  26. INSPECT PACK CLEARANCE OF 1ST AND REVERSE BRAKE


    1. A0155EVE01

      Make sure the 1st and reverse brake piston moves smoothly when applying and releasing compressed air into the transmission case.

  27. INSPECT PISTON STROKE OF NO. 1 BRAKE PISTON


    1. A0155NLE01

      Make sure the No. 1 brake piston moves smoothly when applying and releasing compressed air into the transmission case.

    2. A0159L6E01

      Using a feeler gauge, measure the B3 bearing pack clearance between the snap ring and flange.

      Standard piston stroke
      0.42 to 0.72 mm (0.0165 to 0.0283 in.)

      If the piston stroke is outside the specification, parts may have been assembled incorrectly. Perform the reassembly again. If the piston stroke is still outside the specification, select another flange.

      Tech Tips

      There are 4 different thicknesses for the flange.

  28. INSPECT PACK CLEARANCE OF DIRECT CLUTCH


    1. A015BT1E02

      Using a dial indicator, measure the moving distance (distance A) of the clutch flange at both ends across a diameter while applying air to the oil hole as shown in the illustration, and calculate the average.

      Standard pack clearance
      0.5 to 0.8 mm (0.0197 to 0.0315 in.)

      Note

      When measuring the moving distance, install a standard flange (thickness: 3.4 mm (0.134 in.)) to the position of the shaded area in the illustration.

      Tech Tips

      Flange moving distance A = 0.26 to 1.14 mm (0.0102 to 0.0449 in.)

      Pack clearance = Flange moving distance A - 0.05 mm (0.00197 in.)

      If the pack clearance is outside the standard, select and install a clutch flange that makes the pack clearance within the standard.

      Flange Thickness
      Mark Thickness
      2 2.95 to 3.05 mm (0.116 to 0.120 in.)
      3 3.05 to 3.15 mm (0.120 to 0.124 in.)
      4 3.15 to 3.25 mm (0.124 to 0.128 in.)
      5 3.25 to 3.35 mm (0.128 to 0.132 in.)
      6 3.35 to 3.45 mm (0.132 to 0.136 in.)
      7 3.45 to 3.55 mm (0.136 to 0.140 in.)
      8 3.55 to 3.65 mm (0.140 to 0.144 in.)
      9 3.65 to 3.75 mm (0.144 to 0.148 in.)
      A 3.75 to 3.85 mm (0.148 to 0.152 in.)

  29. INSPECT PACK CLEARANCE OF REVERSE CLUTCH


    1. Using a dial indicator, measure the reverse clutch piston stroke (distance A) and the moving distance (distance B) of the reverse flange at both ends across a diameter while applying air (392 kPa (4.0 kgf/cm2, 57 psi)) to the oil hole as shown in the illustration, and calculate the average.

      Standard pack clearance
      0.5 to 0.8 mm (0.0197 to 0.0315 in.)

      Note

      When measuring the moving distance, install a standard flange (thickness: 3.3 mm (0.130 in.)) to the position of the shaded area in the illustration.

      Tech Tips

      Piston stroke A = 1.05 to 2.15 mm (0.0413 to 0.0846 in.)

      Flange moving distance B = 0.72 to 1.08 mm (0.0283 to 0.0425 in.)

      Pack clearance = Piston stroke A - Flange moving distance B - 0.06 mm (0.00236 in.)

      A015DCSE02

      If the pack clearance is outside the standard, select and install a clutch flange that makes the pack clearance within the standard.

      Flange Thickness
      Mark Thickness
      0 2.75 to 2.85 mm (0.108 to 0.112 in.)
      1 2.85 to 2.95 mm (0.112 to 0.116 in.)
      2 2.95 to 3.05 mm (0.116 to 0.120 in.)
      3 3.05 to 3.15 mm (0.120 to 0.124 in.)
      4 3.15 to 3.25 mm (0.124 to 0.128 in.)
      5 3.25 to 3.35 mm (0.128 to 0.132 in.)
      6 3.35 to 3.45 mm (0.132 to 0.136 in.)
      7 3.45 to 3.55 mm (0.136 to 0.140 in.)
      8 3.55 to 3.65 mm (0.140 to 0.144 in.)
      9 3.65 to 3.75 mm (0.144 to 0.148 in.)
      A 3.75 to 3.85 mm (0.148 to 0.152 in.)

  30. INSPECT PACK CLEARANCE OF FORWARD CLUTCH


    1. A015DWEE02

      Using a dial indicator, measure the moving distance (distance A) of the clutch flange at both ends across a diameter while applying air to the oil hole as shown in the illustration, and calculate the average.

      Standard pack clearance
      0.6 to 0.9 mm (0.0236 to 0.0354 in.)

      Note

      When measuring the moving distance, install a standard flange (thickness: 3.4 mm (0.134 in.)) to the position of the shaded area in the illustration.

      Tech Tips

      Flange moving distance A = 0.26 to 1.36 mm (0.0102 to 0.0535 in.)

      Pack clearance = Flange moving distance A - 0.01 mm (0.000394 in.)

      If the pack clearance is outside the standard, select and install a clutch flange that makes the pack clearance within the standard.

      Flange Thickness
      Mark Thickness
      0 2.95 to 3.05 mm (0.116 to 0.120 in.)
      1 3.05 to 3.15 mm (0.120 to 0.124 in.)
      2 3.15 to 3.25 mm (0.124 to 0.128 in.)
      3 3.25 to 3.35 mm (0.128 to 0.132 in.)
      4 3.35 to 3.45 mm (0.132 to 0.136 in.)
      5 3.45 to 3.55 mm (0.136 to 0.140 in.)
      6 3.55 to 3.65 mm (0.140 to 0.144 in.)
      7 3.65 to 3.75 mm (0.144 to 0.148 in.)
      8 3.75 to 3.85 mm (0.148 to 0.152 in.)
      9 3.85 to 3.95 mm (0.148 to 0.152 in.)
      A 3.95 to 4.05 mm (0.152 to 0.159 in.)

  31. INSPECT INDIVIDUAL PISTON OPERATION


    1. A015BLKE02

      Check the operating sound while applying compressed air into the oil holes indicated in the illustration.

      Tech Tips

      When inspecting the O/D direct clutch, check with the accumulator piston holes indicated in the illustration.

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


      1. No. 2 clutch (C2)

      2. No. 3 clutch (C3)

      3. No. 1 clutch (C1)

      4. No. 3 brake (B3)

      5. No. 1 brake (B1)

      6. No. 2 brake (B2)

      7. No. 4 brake (B4)