AUTOMATIC TRANSAXLE UNIT INSPECTION

  1. INSPECT TRANSMISSION OIL CLEANER MAGNET

    1. Use the removed magnets to collect any steel chips. Examine the chips and particles in the pan and on the magnets to determine what type of wear has occurred in the transaxle:

      A011TVX
      Result
      Steel (magnetic)
      Bearing, gear and plate wear
      Brass (non-magnetic)
      Bushing wear

  2. INSPECT INPUT SHAFT SUB-ASSEMBLY

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

      A011QZS
      End play
      0.012 to 1.250 mm (0.000473 to 0.0492 in.)

  3. INSPECT NO. 2 CLUTCH DISC

    1. Check if the contact surfaces of the discs, plates and flange are worn or burnt.

      A011QOG

      Note

      • If the lining of any disc is peeled off or discolored, or even if part of the groove is damaged, replace all discs.

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

      If necessary, replace them.

  4. INSPECT PLANETARY SUN GEAR SUB-ASSEMBLY

    1. Using a dial indicator, measure the inside diameter of the bushings of the planetary sun gear.

      A011UM5
      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.

  5. INSPECT NO. 1 CLUTCH DISC

    1. Check if the contact surfaces of the discs, plates and flange are worn or burnt.

      A011TYW

      Note

      • If the lining of any disc is peeled off or discolored, or even if part of the groove is damaged, replace all discs.

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

      If necessary, replace them.

  6. INSPECT NO. 3 BRAKE DISC

    1. Check if the contact surfaces of the discs, plates and flanges are worn or burnt.

      A011SSS

      Note

      • If the lining of any disc is peeled off or discolored, or even if part of the groove is damaged, replace all discs.

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

      If necessary, replace them.

  7. INSPECT UNDERDRIVE PLANETARY GEAR ASSEMBLY

    1. Using a feeler gauge, measure the clearance between the underdrive planetary gear and the pinion gear at 4 points.

      A011V1Z
      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.

  8. INSPECT REAR PLANETARY SUN GEAR ASSEMBLY

    1. Using a dial indicator, measure the inside diameter of the bushing of the rear planetary sun gear sub-assembly.

      A011SZR
      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. Check if the contact surfaces of the discs, plates and flange are worn or burnt.

      A011SSS

      Note

      • If the lining of any disc is peeled off or discolored, or even if part of the groove is damaged, replace all discs.

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

      If necessary, replace them.

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

    1. Using a vernier caliper, measure the free length of the 3 2nd brake piston return springs including the spring seats.

      A011RV0
      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.

  11. INSPECT ONE-WAY CLUTCH ASSEMBLY

    1. Temporarily install the one-way clutch assembly to the planetary ring gear.

      A011ROTE05
      Text in Illustration
      *1 Planetary Ring Gear
      *2 One-way Clutch Assembly
      *a Free
      *b Lock

    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 PLANETARY GEAR ASSEMBLY

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

      A011TMQE01
      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 planetary gear assembly.

  13. INSPECT NO. 2 BRAKE DISC

    1. Check if the contact surfaces of the discs, plates and flange are worn or burnt.

      A011TXS

      Note

      • If the lining of any disc is peeled off or discolored, or even if part of the groove is damaged, replace all discs.

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

      If necessary, replace them.

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

    A011RAT

    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 shorter than the standard free length, replace the 1st and reverse brake return spring.

  15. INSPECT CLEARANCE OF NO. 2 BRAKE

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

      A011VBI
      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.

      Tech Tips

      There are 5 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

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

      A011SJR
      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.

      Tech Tips

      There are 6 flanges of different thicknesses.

      No. 1 Brake 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)

  17. INSPECT CLEARANCE OF NO. 3 BRAKE

    1. 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.

      A011TWRE04
      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

      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 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 brake flange so that the clearance will be within the specified range.

      Tech Tips

      There are 6 flanges of different thicknesses.

      No. 3 Brake Flange Thickness: mm (in.)
      Mark Thickness
      38 3.80 (0.150)
      39 3.90 (0.154)
      40 4.00 (0.157)
      41 4.10 (0.161)
      42 4.20 (0.165)
      43 4.30 (0.169)

  18. INSPECT CLEARANCE OF NO. 1 CLUTCH DISC

    Note

    There are two different types of rear multiple disc clutch assembly. Refer to the illustration and visually inspect the rear multiple disc clutch assembly to determine if it is transaxle serial number 2########## or transaxle serial number 3##########.

    A011U3XE01
    Text in Illustration
    *a Transaxle serial number 2##########
    *b Transaxle serial number 3##########

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

      A011S4H

    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).

      Tech Tips

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

      Pack clearance
      0.606 to 0.774 mm (0.0238 to 0.0305 in.)

      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.

      Tech Tips

      There are 7 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)
      36* 3.6 (0.142)*

      Tech Tips

      *Transaxle serial number 3########## only

  19. INSPECT CLEARANCE OF NO. 2 CLUTCH DISC

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

      A011TLJ

    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).

      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.

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

      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.

      Tech Tips

      There are 7 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)
      36* 3.6 (0.142)*

      Tech Tips

      *Transaxle serial number 3########## only