AUTOMATIC TRANSMISSION UNIT(for 8GR-FKS) INSPECTION

PROCEDURE


  1. INSPECT TRANSMISSION DRIVE CHAIN


    1. Check the transmission drive chain for wear or damage.

      If any of the following defects is found, replace the transmission drive chain.

  2. INSPECT OIL PUMP DRIVE SHAFT SUB-ASSEMBLY


    1. Check the oil pump drive shaft sub-assembly for wear or damage.

      If any of the following defects is found, replace the oil pump drive shaft sub-assembly.

  3. INSPECT DRIVE SPROCKET


    1. Check the drive sprocket for wear or damage.

      If any of the following defects is found, replace the drive sprocket.

  4. INSPECT FRONT OIL PUMP ASSEMBLY


    1. B006GO9

      Using a caliper gauge, measure the inside diameter of the front oil pump assembly bushing.

      Standard Inside Diameter
      25.900 to 25.926 mm (1.0197 to 1.0207 in.)

      If the inside diameter is not as specified, replace the front oil pump assembly.

  5. INSPECT NO. 1 BRAKE DISC


    1. B006EIO

      Check if the contact surfaces of the No. 1 brake discs, No. 1 brake plates and No. 1 brake flange are worn or burnt.

      If necessary, replace them.

      Note


      • If the lining of any No. 1 brake disc is peeled or discolored, or even if part of a groove is damaged, replace all of the No. 1 brake discs.

      • Before installing new No. 1 brake discs, soak them in ATF for at least 15 minutes.

  6. INSPECT 2ND BRAKE RETURN WITH RETAINER SPRING SUB-ASSEMBLY


    1. B006BZ9

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

      Standard Free Length
      15.26 mm (0.601 in.)

      If the free length is less than the standard free length, replace the 2nd brake return with retainer spring sub-assembly.

  7. INSPECT PISTON STROKE OF NO. 1 BRAKE


    1. Inspect the piston stroke.


      1. Using a dial indicator, measure the clearance (Dimension (A)) of the No. 1 brake at several points while applying compressed air (400 kPa (4.1 kgf/cm2, 58 psi)) to the oil hole as shown in the illustration, and calculate the average.

        B006GGCC01
        *A Front Side *B Rear Side
        *a Blow air into the oil hole *b Cover the oil hole
        B006E97 No. 1 Brake Flange - -
        Standard Clearance
        0.957 to 1.642 mm (0.0377 to 0.0646 in.)

        Tech Tips

        The value is the average value obtained by measuring the dimension at 3 positions.

        If the clearance is not as specified, check the installation condition, dimensions of each part and adjust the piston stroke.

    2. Adjust the piston stroke.


      1. Select the No. 1 brake flange and adjust the piston stroke value.

        Standard Clearance
        1.200 to 1.400 mm (0.0473 to 0.0551 in.)

        Tech Tips

        There are 7 No. 1 brake flanges of different thicknesses.

        No. 1 Brake Flange Thickness
        Part No. Mark Thickness
        35676-11120 0 3.15 to 3.25 mm (0.125 to 0.127 in.)
        35676-11130 1 3.25 to 3.35 mm (0.128 to 0.131 in.)
        35676-11140 2 3.35 to 3.45 mm (0.132 to 0.135 in.)
        35676-11150 3 3.45 to 3.55 mm (0.136 to 0.139 in.)
        35676-11160 4 3.55 to 3.65 mm (0.140 to 0.143 in.)
        35676-11170 5 3.65 to 3.75 mm (0.144 to 0.147 in.)
        35676-11180 6 3.75 to 3.85 mm (0.148 to 0.151 in.)

  8. INSPECT FRONT PLANETARY SUN GEAR SUB-ASSEMBLY


    1. B006BT0

      Using a caliper gauge, measure the inside diameter of the front planetary sun gear sub-assembly bushing.

      Standard Inside Diameter
      56.02 to 56.04 mm (2.2056 to 2.2062 in.)

      If the inside diameter is not as specified, replace the front planetary sun gear sub-assembly.

  9. INSPECT FRONT PLANETARY GEAR ASSEMBLY


    1. B006G8B

      Using a feeler gauge, measure the clearance between the front planetary gear assembly and each pinion gear.

      Standard Clearance
      0.20 to 0.60 mm (0.00788 to 0.0236 in.)

      If the clearance is not as specified, replace the front planetary gear assembly.

  10. INSPECT NO. 2 CLUTCH DISC


    1. B006F6V

      Check if the contact surfaces of the No. 2 clutch discs, No. 2 clutch plates and No. 2 clutch flange are worn or burnt.

      If necessary, replace them.

      Note


      • If the lining of any No. 2 clutch disc is peeled or discolored, or even if part of the printed number is damaged, replace all the No. 2 clutch discs.

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

  11. INSPECT DIRECT CLUTCH RETURN SPRING SUB-ASSEMBLY (C-2 CLUTCH)


    1. B006AAN

      Using a vernier caliper, measure the free length of the direct clutch return spring sub-assembly (C-2 clutch) including the spring seat.

      Standard Free Length
      14.84 mm (0.584 in.)

      If the free length is less than the standard free length, replace the direct clutch return spring sub-assembly (C-2 clutch).

  12. INSPECT PISTON STROKE OF NO. 2 CLUTCH


    1. Inspect the piston stroke.


      1. B0069XGC01
        *a Blow air into the oil hole
        B006E97 No. 2 Clutch Flange

        Using a dial indicator, measure the clearance (Dimension (A)) of the No. 2 clutch at several points while applying compressed air (400 kPa (4.1 kgf/cm2, 58 psi)) to the oil hole as shown in the illustration, and calculate the average.

        Standard Clearance
        0.9527 to 1.7673 mm (0.0376 to 0.0695 in.)

        Tech Tips

        The value is the average value obtained by measuring the dimension at 3 positions.

        If the clearance is not as specified, check the installation condition, dimensions of each part and adjust the piston stroke.

    2. Adjust the piston stroke.


      1. Select the No. 2 clutch flange and adjust the piston stroke value.

        Standard Clearance
        1.260 to 1.460 mm (0.0497 to 0.0574 in.)

        Tech Tips

        There are 9 No. 2 clutch flanges of different thicknesses.

        No. 2 Clutch Flange Thickness
        Part No. Mark Thickness
        35635-11270 0 3.05 to 3.15 mm (0.121 to 0.124 in.)
        35635-11280 1 3.15 to 3.25 mm (0.125 to 0.127 in.)
        35635-11290 2 3.25 to 3.35 mm (0.128 to 0.131 in.)
        35635-11300 3 3.35 to 3.45 mm (0.132 to 0.135 in.)
        35635-11310 4 3.45 to 3.55 mm (0.136 to 0.139 in.)
        35635-11320 5 3.55 to 3.65 mm (0.140 to 0.143 in.)
        35635-11330 6 3.65 to 3.75 mm (0.144 to 0.147 in.)
        35635-11340 7 3.75 to 3.85 mm (0.148 to 0.151 in.)
        35635-11350 8 3.85 to 3.95 mm (0.152 to 0.155 in.)

  13. INSPECT PISTON STROKE OF C-1 CLUTCH ASSEMBLY

    Note

    Do not disassemble the C-1 clutch assembly.

    If disassembled, replace the C-1 clutch assembly with a new one.


    1. Inspect the piston stroke.


      1. B006AL1C01
        *a Blow air into the oil hole
        *b Cover the 4 oil holes
        B006E97 No. 1 Clutch Flange

        Using a dial indicator, measure the clearance (Dimension (A)) of the No. 1 clutch at several points while applying compressed air (400 kPa (4.1 kgf/cm2, 58 psi)) to the oil hole as shown in the illustration, and calculate the average.

        Standard Clearance
        1.046 to 1.853 mm (0.0412 to 0.0729 in.)

        Tech Tips

        The value is the average value obtained by measuring the dimension at 3 positions.

        If the clearance is not as specified, replace the C-1 clutch assembly.

  14. INSPECT C-1 CLUTCH ASSEMBLY

    Note

    Do not disassemble the C-1 clutch assembly.

    If disassembled, replace the C-1 clutch assembly with a new one.


    1. B0069I5C01
      *A Front Side
      *B Rear Side

      Using a caliper gauge, measure the inside diameter of the C-1 clutch assembly bushing.

      Standard Inside Diameter (Front Side)
      47.021 to 47.046 mm (1.8513 to 1.8522 in.)
      Standard Inside Diameter (Rear Side)
      42.012 to 42.037 mm (1.6541 to 1.6550 in.)

      If the inside diameter is not as specified, replace the C-1 clutch assembly.

  15. INSPECT NO. 2 BRAKE DISC


    1. B006FIG

      Check if the contact surfaces of the No. 2 brake discs, No. 2 brake plates and No. 2 brake flange are worn or burnt.

      If necessary, replace them.

      Note


      • If the lining of any No. 2 brake disc is peeled or discolored, or even if part of the printed number is damaged, replace all the No. 2 brake discs.

      • Before installing new No. 2 brake discs, soak them in ATF for at least 15 minutes.

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


    1. B006D3R

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

      Standard Free Length
      15.66 mm (0.617 in.)

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

  17. INSPECT PISTON STROKE OF NO. 2 BRAKE


    1. Inspect the piston stroke.


      1. B006ANEC01
        *a Blow air into the oil hole
        B006E97 No. 2 Brake Flange

        Using a dial indicator, measure the clearance (Dimension (A)) of the No. 2 brake at several points while applying compressed air (200 kPa (2.0 kgf/cm2, 29 psi)) to the oil hole as shown in the illustration, and calculate the average.

        Standard Clearance
        0.886 to 1.714 mm (0.0349 to 0.0674 in.)

        Tech Tips

        The value is the average value obtained by measuring the dimension at 3 positions.

        If the clearance is not as specified, check the installation condition, dimensions of each part and adjust the piston stroke.

    2. Adjust the piston stroke.


      1. Select the No. 2 brake flange and adjust the piston stroke value.

        Standard Clearance
        1.08 to 1.28 mm (0.0426 to 0.0503 in.)

        Tech Tips

        There are 9 No. 2 brake flanges of different thicknesses.

        No. 2 Brake Flange Thickness
        Part No. Mark Thickness
        35678-11100 0 5.95 to 6.05 mm (0.235 to 0.238 in.)
        35678-11110 1 6.05 to 6.15 mm (0.239 to 0.242 in.)
        35678-11120 2 6.15 to 6.25 mm (0.243 to 0.246 in.)
        35678-11130 3 6.25 to 6.35 mm (0.247 to 0.250 in.)
        35678-11140 4 6.35 to 6.45 mm (0.251 to 0.253 in.)
        35678-11150 5 6.45 to 6.55 mm (0.254 to 0.257 in.)
        35678-11160 6 6.55 to 6.65 mm (0.258 to 0.261 in.)
        35678-11170 7 6.65 to 6.75 mm (0.262 to 0.265 in.)
        35678-11180 8 6.75 to 6.85 mm (0.266 to 0.269 in.)

  18. INSPECT NO. 3 CLUTCH DISC


    1. B006BI3

      Check if the contact surfaces of the No. 3 clutch discs, No. 3 clutch plates and clutch flange are worn or burnt.

      If necessary, replace them.

      Note


      • If the lining of any No. 3 clutch disc is peeled or discolored, or even if part of a groove is damaged, replace all of the No. 3 clutch discs.

      • Before installing new No. 3 clutch discs, soak them in ATF for at least 15 minutes.

  19. INSPECT DIRECT CLUTCH RETURN SPRING SUB-ASSEMBLY (C-3 CLUTCH)


    1. B006EYX

      Using a vernier caliper, measure the free length of the direct clutch return spring sub-assembly (C-3 clutch) including the spring seat.

      Standard Free Length
      17.56 mm (0.691 in.)

      If the free length is less than the standard free length, replace the direct clutch return spring sub-assembly (C-3 clutch).

  20. INSPECT PISTON STROKE OF NO. 3 CLUTCH


    1. Inspect the piston stroke.


      1. B0069MTC01
        *a Blow air into the oil hole
        B006E97 Clutch Flange

        Using a dial indicator, measure the clearance (Dimension (A)) of the No. 3 clutch at several points while applying compressed air (400 kPa (4.1 kgf/cm2, 58 psi)) to the oil hole as shown in the illustration, and calculate the average.

        Standard Clearance
        0.671 to 1.529 mm (0.0265 to 0.0601 in.)

        Tech Tips

        The value is the average value obtained by measuring the dimension at 3 positions.

        If the clearance is not as specified, check the installation condition, dimensions of each part and adjust the piston stroke.

    2. Adjust the piston stroke.


      1. Select the clutch flange and adjust the piston stroke value.

        Standard Clearance
        1.000 to 1.200 mm (0.0394 to 0.0472 in.)

        Tech Tips

        There are 9 clutch flanges of different thicknesses.

        Clutch Flange Thickness
        Part No. Mark Thickness
        35635-11380 0 3.05 to 3.15 mm (0.121 to 0.124 in.)
        35635-11390 1 3.15 to 3.25 mm (0.125 to 0.127 in.)
        35635-11400 2 3.25 to 3.35 mm (0.128 to 0.131 in.)
        35635-11410 3 3.35 to 3.45 mm (0.132 to 0.135 in.)
        35635-11420 4 3.45 to 3.55 mm (0.136 to 0.139 in.)
        35635-11430 5 3.55 to 3.65 mm (0.140 to 0.143 in.)
        35635-11440 6 3.65 to 3.75 mm (0.144 to 0.147 in.)
        35635-11450 7 3.75 to 3.85 mm (0.148 to 0.151 in.)
        35635-11460 8 3.85 to 3.95 mm (0.152 to 0.155 in.)

  21. INSPECT CENTER SUPPORT SUB-ASSEMBLY


    1. B006GL2

      Using a caliper gauge, measure the inside diameter of the center support sub-assembly bushing.

      Standard Inside Diameter
      64.720 to 64.745 mm (2.5481 to 2.5490 in.)

      If the inside diameter is not as specified, replace the center support sub-assembly.

  22. INSPECT CENTER PLANETARY GEAR ASSEMBLY


    1. B006DTJ

      Using a feeler gauge, measure the clearance between the center planetary gear assembly and each pinion gear.

      Standard Clearance
      0.20 to 0.60 mm (0.00788 to 0.0236 in.)

      If the clearance is not as specified, replace the center planetary gear assembly.

  23. INSPECT PLANETARY SUN GEAR SUB-ASSEMBLY


    1. B006EIRC01
      *A Front Side
      *B Rear Side

      Using a caliper gauge, measure the inside diameter of the planetary sun gear sub-assembly bushing.

      Standard Inside Diameter (Front Side and Rear Side)
      28.000 to 28.021 mm (1.1024 to 1.1031 in.)

      If the inside diameter is not as specified, replace the planetary sun gear sub-assembly.

  24. INSPECT REAR PLANETARY GEAR ASSEMBLY


    1. B006CCD

      Using a feeler gauge, measure the clearance between the rear planetary gear assembly and each pinion gear.

      Standard Clearance
      0.20 to 0.60 mm (0.00788 to 0.0236 in.)

      If the clearance is not as specified, replace the rear planetary gear assembly.

  25. INSPECT REAR PLANETARY RING GEAR FLANGE SUB-ASSEMBLY


    1. B006D2A

      Using a caliper gauge, measure the inside diameter of the rear planetary ring gear flange sub-assembly bushing.

      Standard Inside Diameter
      22.245 to 22.270 mm (0.8758 to 0.8767 in.)

      If the inside diameter is not as specified, replace the rear planetary ring gear flange sub-assembly.

  26. INSPECT NO. 4 CLUTCH DISC


    1. B006GJR

      Check if the contact surfaces of the No. 4 clutch discs, No. 4 clutch plates and clutch flange are worn or burnt.

      If necessary, replace them.

      Note


      • If the lining of any No. 4 clutch disc is peeled or discolored, or even if part of a groove is damaged, replace all of the No. 4 clutch discs.

      • Before installing new No. 4 clutch discs, soak them in ATF for at least 15 minutes.

  27. INSPECT DIRECT CLUTCH RETURN SPRING SUB-ASSEMBLY (C-4 CLUTCH)


    1. B006BCW

      Using a vernier caliper, measure the free length of the direct clutch return spring sub-assembly (C-4 clutch) including the spring seat.

      Standard Free Length
      19.02 mm (0.749 in.)

      If the free length is less than the standard free length, replace the direct clutch return spring sub-assembly (C-4 clutch).

  28. INSPECT PISTON STROKE OF NO. 4 CLUTCH


    1. Inspect the piston stroke.


      1. B006FJVC01
        *a Blow air into the oil hole
        *b Cover the 2 oil holes
        B006E97 Clutch Flange

        Using a dial indicator, measure the clearance (Dimension (A)) of the No. 4 clutch at several points while applying compressed air (400 kPa (4.1 kgf/cm2, 58 psi)) to the oil hole as shown in the illustration, and calculate the average.

        Standard Clearance
        0.50 to 0.90 mm (0.0197 to 0.0354 in.)

        Tech Tips

        The value is the average value obtained by measuring the dimension at 3 positions.

        If the clearance is not as specified, check the installation condition, dimensions of each part and adjust the piston stroke.

    2. Adjust the piston stroke.


      1. Select the clutch flange and adjust the piston stroke value.

        Standard Clearance
        1.080 to 1.280 mm (0.0426 to 0.0503 in.)

        Tech Tips

        There are 9 clutch flanges of different thicknesses.

        Clutch Flange Thickness
        Part No. Thickness
        35635-11470 3.85 to 3.95 mm (0.152 to 0.155 in.)
        35635-11480 3.95 to 4.05 mm (0.156 to 0.159 in.)
        35635-11490 4.05 to 4.15 mm (0.160 to 0.163 in.)
        35635-11500 4.15 to 4.25 mm (0.164 to 0.167 in.)
        35635-11510 4.25 to 4.35 mm (0.168 to 0.171 in.)
        35635-11520 4.35 to 4.45 mm (0.172 to 0.175 in.)
        35635-11530 4.45 to 4.55 mm (0.176 to 0.179 in.)
        35635-11540 4.55 to 4.65 mm (0.180 to 0.183 in.)
        35635-11550 4.65 to 4.75 mm (0.184 to 0.187 in.)

  29. INSPECT INDIVIDUAL PISTON OPERATION


    1. B006G1MC01
      *1 No. 1 Clutch (C-1)
      *2 No. 2 Clutch (C-2)
      *3 No. 3 Clutch (C-3)
      *4 No. 4 Clutch (C-4)
      *5 No. 1 Brake (B-1)
      *6 No. 2 Brake (B-2 (In))
      *7 No. 2 Brake (B-2 (Out))

      Check the operating sound of each piston while applying compressed air to each oil hole shown in the illustration.

  30. INSPECT AUTOMATIC TRANSMISSION CASE


    1. B006CT4

      Using a caliper gauge, measure the inside diameter of the automatic transmission case sleeve bushing.

      Standard Free Length
      43.870 to 43.955 mm (1.7272 to 1.7305 in.)

      If the inside diameter is not as specified, replace the automatic transmission case.