AUTOMATIC TRANSAXLE UNIT INSPECTION


  1. INSPECT AUTOMATIC TRANSAXLE OIL PAN SUB-ASSEMBLY


    1. A01EU2IE01

      Remove the magnets and use them 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.

      Steel (magnetic): bearing, gear and plate wear

      Brass (non-magnetic): bush wear

  2. INSPECT INPUT SHAFT END PLAY


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

    2. A01EXXLE01

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

      Standard end play
      0.262 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.

  3. INSPECT NO. 2 UNDERDRIVE CLUTCH DISC


    1. A01EXEZE01

      Check if the sliding surface of the No. 2 underdrive clutch disc, plate and flange are worn or burnt.

      If necessary, replace them.

      Note


      • If the lining of the No. 2 underdrive clutch disc is peeling off or discolored, or even if a part of the groove is defaced, replace all No. 2 underdrive clutch discs.

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

  4. INSPECT UNDERDRIVE BRAKE RETURN SPRING SUB-ASSEMBLY


    1. A01EU65E01

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

      Standard free length
      14.04 mm (0.553 in.)

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

  5. INSPECT 2ND BRAKE CLUTCH DISC


    1. A01EV15E01

      Check if the sliding surface of the 2nd brake clutch disc, plate and flange are worn or burnt.

      If necessary, replace them.

      Note


      • If the lining of the 2nd brake clutch disc is peeling off or discolored, or even if a part of the printed number is defaced, replace all 2nd brake clutch discs.

      • Before assembling new 2nd brake clutch discs, soak them in ATF for at least 15 minutes.

  6. INSPECT 1ST AND REVERSE BRAKE CLUTCH DISC


    1. A01EV5CE01

      Check if the sliding surface of the 1st and reverse brake clutch disc, plate and flange are worn or burnt.

      If necessary, replace them.

      Note


      • If the lining of the 1st and reverse brake clutch disc is peeling off or discolored, or even if a part of the groove is defaced, replace all 1st and reverse brake clutch discs.

      • Before assembling new 1st and reverse brake clutch discs, soak them in ATF for at least 15 minutes.

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


    1. A01EW0GE01

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

      Standard free length
      15.53 mm (0.611 in.)

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

  8. INSPECT MULTIPLE DISC CLUTCH HUB


    1. A01EW9TE01

      Using a caliper gauge, measure the inside diameter of the multiple disc clutch hub.

      Standard inside diameter
      23.025 to 23.046 mm (0.9065 to 0.9073 in.)
      Maximum inside diameter
      23.09 mm (0.9091 in.)

      Note

      Check the contact surface of the bush in the direct clutch shaft. If any scratch or discolor is identified, replace the direct clutch sub-assembly with a new one.

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

  9. INSPECT PACK CLEARANCE OF FORWARD CLUTCH


    1. A01EV46

      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
      1.41 to 1.75 mm (0.0555 to 0.0688 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 7 different thicknesses of flanges.

      Standard Flange Thickness
      Mark Thickness Mark Thickness
      0 2.85 mm (0.112 in.) 4 3.45 mm (0.1358 in.)
      1 3.00 mm (0.1181 in.) 5 3.60 mm (0.1417 in.)
      2 3.15 mm (0.1240 in.) 6 3.75 mm (0.147 in.)
      3 3.30 mm (0.1299 in.) - -

  10. INSPECT FORWARD MULTIPLE DISC CLUTCH DISC


    1. A01EUTKE01

      Check if the sliding surface of the forward multiple disc clutch disc, plate and flange are worn or burnt.

      If necessary, replace them.

      Note


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

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

  11. INSPECT FORWARD CLUTCH RETURN SPRING SUB-ASSEMBLY


    1. A01EW1RE01

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

      Standard free length
      28.23 mm (1.1114 in.)

      If the result is not as specified, replace the forward clutch return spring sub-assembly.

  12. INSPECT FORWARD CLUTCH PISTON SUB-ASSEMBLY


    1. A01EW31E01

      Shake the forward clutch piston sub-assembly to check that the check ball is not stuck.

    2. A01EU76E01

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

  13. INSPECT UNDERDRIVE PLANETARY GEAR PRELOAD


    1. A01EWKYE03
      Text in Illustration
      *1 Underdrive Planetary Gear

      Using SST, secure the underdrive planetary gear assembly.

      SST
      09387-00050
      09495-65040
    2. A01EWPPE01

      Using SST and a torque wrench, measure the turning torque of the underdrive planetary gear assembly while turning the torque wrench at 60 rpm.

      SST
      09387-00050
      09495-65040
      Turning torque at 60 rpm
      0.28 to 0.89 N*m (2.9 to 9.1 kgf*cm, 2.478 to 7.877 in.*lbf)

      Tech Tips

      Use a torque wrench with a fulcrum length of 160 mm (6.30 in.).

  14. INSPECT UNDERDRIVE CLUTCH PACK CLEARANCE


    1. Install the underdrive clutch to the transaxle case.

      Note

      Be careful not to damage the oil seal rings.

    2. A01ETRQE01

      Install a dial indicator as shown in the illustration.

    3. A01EUFJE01

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

      Standard pack clearance
      1.51 to 1.71 mm (0.0594 to 0.0673 in.)

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

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

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

      Tech Tips

      There are 7 flanges in different thickness.

      Standard Flange Thickness
      Mark Thickness Mark Thickness
      A 3.0 mm (0.118 in.) G 3.1 mm (0.122 in.)
      B 3.2 mm (0.126 in.) H 3.3 mm (0.130 in.)
      C 3.4 mm (0.134 in.) J 3.5 mm (0.138 in.)
      F 2.9 mm (0.114 in.) - -

  15. INSPECT NO. 1 UNDERDRIVE CLUTCH DISC


    1. A01EXMFE01

      Check to see if the sliding surface of the No. 1 underdrive clutch disc, plate and flange are worn or burnt. If necessary, replace them.

      Note


      • If the lining of the No. 1 underdrive clutch disc is peeling off or discolored, replace all No. 1 underdrive clutch discs.

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

  16. INSPECT UNDERDRIVE CLUTCH RETURN SPRING SUB-ASSEMBLY


    1. A01EXPHE01

      Using a vernier caliper, measure the free length of the underdrive clutch return spring sub-assembly together with the spring seat.

      Standard free length
      17.14 mm (0.6748 in.)

      If the result is not as specified, replace the underdrive clutch return spring sub-assembly.

  17. INSPECT UNDERDRIVE CLUTCH DRUM SUB-ASSEMBLY


    1. A01EYO0E02

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

      Standard drum bushing
      32.56 to 32.58 mm (1.2818 to 1.2826 in.)
      Maximum drum bushing
      32.63 mm (1.2846 in.)

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

  18. INSPECT PACK CLEARANCE OF DIRECT CLUTCH


    1. A01EUHME01

      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
      0.652 to 0.872 mm (0.0257 to 0.0343 in.)

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

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

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

      Tech Tips

      There are 8 different thicknesses of flanges.

      Standard Flange Thickness
      Mark Thickness Mark Thickness
      0 2.9 mm (0.114 in.) 4 3.3 mm (0.130 in.)
      1 3.0 mm (0.118 in.) 5 3.4 mm (0.134 in.)
      2 3.1 mm (0.122 in.) 6 3.5 mm (0.138 in.)
      3 3.2 mm (0.126 in.) 7 3.6 mm (0.142 in.)

  19. INSPECT DIRECT MULTIPLE DISC CLUTCH DISC


    1. A01EX8EE01

      Check if the sliding surface of the direct multiple disc clutch disc, plate and flange are worn or burnt.

      If necessary, replace them.

      Note


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

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

  20. INSPECT DIRECT CLUTCH RETURN SPRING SUB-ASSEMBLY


    1. A01EVMRE03

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

      Standard free length
      22.58 mm (0.8890 in.)

      If the result is not as specified, replace the direct clutch return spring sub-assembly.

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


    1. A01EUW8E02

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

      Standard free length
      16.61 mm (0.6539 in.)

      If the result is not as specified, replace the 2nd brake piston return spring sub-assembly.