AUTOMATIC TRANSAXLE UNIT INSPECTION

1. 

   Remove the magnets and use them to collect any steel chips. Look carefully at the chips and particles in the pan and on the magnets to anticipate what type of wear has occurred in the transaxle.

   Steel (magnetic): bearing, gear and plate wear

   Brass (non-magnetic): bush wear

1. Secure the transaxle case with the oil pump side facing up.

2. 

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

   Standard end play
   0.26 to 1.25 mm (0.0103 to 0.0492 in.)

   If the end play is not as specified, replace the stator shaft thrust needle roller bearing and the forward clutch hub thrust needle roller bearing.

Check to see if the sliding surface of the flange, discs and plates are worn or burnt.

If necessary, replace them.

1. 

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

   Standard free length
   14.04 mm (0.5213 in.)

   If the free length is shorter than the standard free length, replace the under drive brake return spring sub-assembly.

1. 

   Check to see if the sliding surface of the flange, discs and plates are worn or burnt.

   If necessary, replace them.

   Tech Tips

   
   

   • If the lining of the disc is peeling off or discolored, or even if a part of the printed number is defaced, replace all discs.

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

1. 

   Check to see if the sliding surface of the flange, discs and plates are worn or burnt.

   If necessary, replace them.

   Tech Tips

   
   

   • If the lining of the disc is peeling off or discolored, or even if a part of the groove is defaced, replace all discs.

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

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
   15.51 mm (0.6106 in.)

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

1. 

   Using a caliper gauge, measure the inside diameter of the forward clutch hub bush.

   Standard inside diameter
   23.025 to 23.045 mm (0.9065 to 0.9073 in.)

   Maximum inside diameter
   23.09 mm (0.9091 in.)

   Note

   
   

   • When the diameter is over the maximum, replace the multiple disc clutch hub with a new one.

   • Check the contact surface of the bush in the direct clutch shaft. If there are any scratches or discoloration, replace the direct clutch sub-assembly with a new one.

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

1. 

   Install the forward clutch on the oil pump.

   Note

   Be careful not to damage the oil seal ring of the oil pump.

2. Using a dial indicator, measure the forward clutch piston stroke while applying and releasing compressed air (392 kPa, 4.0 kgf/cm², 57 psi).

   Standard piston stroke
   1.74 to 2.08 mm (0.0685 to 0.0819 in.)

   If the piston stroke is less than the minimum, the parts may have been assembled incorrectly. Check and reassemble again.

   If the clearance is not as specified, select another flange.

   Tech Tips

   There are 5 different thicknesses of flanges.

   Standard flange thickness
   No. Thickness No. Thickness 1 3.00 mm (0.1181 in.) 4 3.45 mm (0.1358 in.) 2 3.15 mm (0.1240 in.) 5 3.60 mm (0.1417 in.) 3 3.30 mm (0.1299 in.) - -

1. 

   Check to see if the sliding surface of the flange, discs and plates are worn or burnt.

   If necessary, replace them.

   Tech Tips

   
   

   • If the lining of the disc is peeling off or discolored, replace all discs.

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

1. 

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

   Standard free length
   28.23 mm (1.1114 in.)

   If the result is not as specified, replace the spring.

1. 

   Shake the piston to check that the check ball is not stuck.

2. 

   Check that the valve does not leak when applying low compressed air (392 kPa, 4.0 kgf/cm², 57 psi).

1. Install the underdrive clutch to the transaxle case.

   Note

   Be careful not to damage the oil seal rings.

2. 

   Install a dial indicator as shown in the illustration.

3. 

   Measure the underdrive clutch pack clearance while applying and releasing compressed air (392 kPa, 4.0 kgf/cm², 57 psi).

   Standard pack clearance
   1.51 to 1.90 mm (0.0594 to 0.0748 in.)

   If the pack clearance is not as specified, inspect the discs, plates and flange.

   If the park clearance is not as specified, select another flange.

   Tech Tips

   There are 3 flanges in different thickness.

   Standard flange thickness
   No. Thickness No. Thickness A 3.0 mm (0.118 in.) C 3.4 mm (0.134 in.) B 3.2 mm (0.126 in.) - -

1. 

   Check to see if the sliding surface of the flange, discs and plates are worn or burnt. If necessary, replace them.

   Tech Tips

   
   

   • If the lining of the disc is peeling off or discolored, or even if a part of the printed mark is defaced, replace all discs.

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

1. 

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

   Standard free length
   17.14 mm (0.6748 in.)

   If the result is not as specified, replace the spring.

1. 

   Using a caliper gauge, measure the inside diameter of the underdrive clutch drum bush.

   Standard drum bush
   32.56 to 32.58 mm (1.2818 to 1.2826 in.)

   Maximum drum bush
   32.63 mm (1.2846 in.)

   If the inside diameter is greater than the maximum, replace the underdrive clutch drum sub-assembly.

1. 

   Install the direct clutch and needle roller bearing on the transaxle rear cover.

2. Using a dial indicator, measure the direct clutch pack clearance while applying and releasing compressed air (392 kPa, 4.0 kgf/cm², 57 psi).

   Standard pack clearance
   0.605 to 0.825 mm (0.02382 to 0.03248 in.)

   If the pack clearance is less than the minimum, parts may have been assembled incorrectly, so check and reassemble again.

   If the stroke is not as specified, select another flange.

   Tech Tips

   There are 6 flanges in different thickness.

   Standard Flange Thickness
   No. Thickness No. Thickness 1 3.0 mm (0.118 in.) 4 3.3 mm (0.130 in.) 2 3.1 mm (0.122 in.) 5 3.4 mm (0.134 in.) 3 3.2 mm (0.126 in.) 6 3.5 mm (0.138 in.)

1. 

   Check to see if the sliding surface of the flange, discs and plates are worn or burnt.

   If necessary, replace them.

   Tech Tips

   
   

   • If the lining of the disc is peeling off or discolored, or even if a part of the printed mark is defaced, replace all discs.

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

1. 

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

   Standard free length
   22.58 mm (0.8890 in.)

   If the result is not as specified, replace the spring.

1. 

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

   Standard free length
   16.61 mm (0.6539 in.)

   If the result is not as specified, replace the spring.