AUTOMATIC TRANSAXLE UNIT INSPECTION

PROCEDURE

  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:

      Result

      Steel (magnetic)

      Bearing, gear and plate wear

      Brass (non-magnetic)

      Bushing wear

  2. INSPECT INPUT SHAFT SUB-ASSEMBLY

    1. C136696

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

      End play

      0.012 to 1.250 mm (0.000473 to 0.0492 in.)

  3. INSPECT NO. 2 CLUTCH DISC

    1. C138267

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

      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. C138259

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

      Standard inside diameter

      25.525 to 25.546 mm (1.0050 to 1.0057 in.)

      Maximum inside diameter

      25.546 mm (1.0057 in.)

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

  5. INSPECT NO. 1 CLUTCH DISC

    1. C138265

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

      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. C138255

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

      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. C291374

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

      Standard clearance

      0.18 to 0.54 mm (0.00709 to 0.0212 in.)

      If the clearance is more than the standard clearance, replace the underdrive planetary gear.

  8. INSPECT REAR PLANETARY SUN GEAR ASSEMBLY

    1. C138266

      Using a caliper gauge, measure the inside diameter of the bushing of the rear planetary sun gear sub-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 more than the maximum, replace the rear planetary sun gear assembly.

  9. INSPECT NO. 1 BRAKE DISC

    1. C138255

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

      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. C138254

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

      Standard free length

      23.85 mm (0.939 in.)

      If the free length is less than the standard free length, replace the 2nd brake piston return spring.

  11. INSPECT ONE-WAY CLUTCH ASSEMBLY

    1. C189425C02

      *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. C137433N01

      Using a feeler gauge, measure the clearance between the 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 more than the standard clearance, replace the planetary gear assembly.

  13. INSPECT NO. 2 BRAKE DISC

    1. C137438

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

      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

    C141533

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

  15. INSPECT CLEARANCE OF NO. 2 BRAKE

    1. C137439

      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 0.0470 in.)

      Tip:

      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.

      Tip:

      There are 5 flanges of different thicknesses.

      Table 1. No. 2 Brake Flange Thickness:

      Mark

      Thickness

      40

      4.0 mm (0.157 in.)

      41

      4.1 mm (0.161 in.)

      42

      4.2 mm (0.165 in.)

      43

      4.3 mm (0.169 in.)

      44

      4.4 mm (0.173 in.)

  16. INSPECT CLEARANCE OF NO. 1 BRAKE

    1. C138258

      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.)

      Tip:

      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.

      Tip:

      There are 6 flanges of different thicknesses.

      Table 2. No. 1 Brake Flange Thickness:

      Mark

      Thickness

      30

      3.0 mm (0.118 in.)

      31

      3.1 mm (0.122 in.)

      32

      3.2 mm (0.126 in.)

      33

      3.3 mm (0.130 in.)

      34

      3.4 mm (0.134 in.)

      35

      3.5 mm (0.138 in.)

      36

      3.6 mm (0.142 in.)

  17. INSPECT CLEARANCE OF NO. 3 BRAKE

    1. C138724C01

      *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.

      Tip:

      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).

      Tip:

      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.

      Tip:

      There are 6 flanges of different thicknesses.

      Table 3. No. 3 Brake Flange Thickness:

      Mark

      Thickness

      38

      3.80 mm (0.150 in.)

      39

      3.90 mm (0.154 in.)

      40

      4.00 mm (0.157 in.)

      41

      4.10 mm (0.161 in.)

      42

      4.20 mm (0.165 in.)

      43

      4.30 mm (0.169 in.)

      44

      4.40 mm (0.173 in.)

      45

      4.50 mm (0.177 in.)

  18. INSPECT CLEARANCE OF NO. 1 CLUTCH DISC

    1. C138728

      Install the direct multiple disc clutch assembly onto 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).

      Tip:

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

      Pack clearance

      0.806 to 0.974 mm (0.0317 to 0.0383 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.

      Tip:

      There are 7 flanges of different thicknesses.

      Table 4. No. 1 Clutch Flange Thickness:

      Mark

      Thickness

      30

      3.0 mm (0.118 in.)

      31

      3.1 mm (0.122 in.)

      32

      3.2 mm (0.126 in.)

      33

      3.3 mm (0.130 in.)

      34

      3.4 mm (0.134 in.)

      35

      3.5 mm (0.138 in.)

  19. INSPECT CLEARANCE OF NO. 2 CLUTCH DISC

    1. C138727

      Install the direct multiple disc clutch assembly onto 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).

      Tip:

      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 (0.0215 to 0.0292 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.

      Tip:

      There are 7 flanges of different thicknesses.

      Table 5. No. 2 Clutch Flange Thickness:

      Mark

      Thickness

      30

      3.0 mm (0.118 in.)

      31

      3.1 mm (0.122 in.)

      32

      3.2 mm (0.126 in.)

      33

      3.3 mm (0.130 in.)

      34

      3.4 mm (0.134 in.)

      35

      3.5 mm (0.138 in.)