AUTOMATIC TRANSAXLE UNIT INSPECTION

PROCEDURE


  1. INSPECT TRANSMISSION OIL CLEANER MAGNET


    1. B005MSY

      Use the removed transmission oil cleaner magnets to collect any steel chips. Examine the chips and particles in the automatic transaxle oil pan sub-assembly and on the transmission oil cleaner magnets to determine what type of wear might be found in the automatic transaxle assembly.

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

  2. INSPECT INPUT SHAFT SUB-ASSEMBLY END PLAY


    1. B005O2X

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

      Standard End Play
      0.012 to 1.250 mm (0.000472 to 0.0492 in.)

  3. INSPECT INTERMEDIATE SHAFT END PLAY


    1. B007WYKC03
      *a Dimension (A)

      Clean the contact surfaces of the transaxle case sub-assembly and rear transaxle cover sub-assembly.

    2. Place a straightedge on the multiple direct clutch drum and measure the distance between the transaxle case sub-assembly and the straightedge (Dimension (A)) using a vernier caliper.

    3. B007XRPC08
      *a Dimension (B)

      Using a vernier caliper and a straightedge, measure the distance shown in the illustration (Dimension (B)).

    4. Calculate the end play using the following formula:

      End play = Dimension (B) - Dimension (A) - Thrust needle roller bearing thickness

      Standard End Play
      0.007 to 1.113 mm (0.000276 to 0.0438 in.)

  4. INSPECT PLANETARY SUN GEAR SUB-ASSEMBLY


    1. B005PAF

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

      Standard Inside Diameter
      25.525 to 25.546 mm (1.00 to 1.01 in.)
      Maximum Inside Diameter
      25.546 mm (1.01 in.)

      If the inside diameter is greater than the maximum, replace the planetary sun gear sub-assembly.

  5. INSPECT REAR PLANETARY SUN GEAR ASSEMBLY


    1. B005LW8

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

      Standard Inside Diameter
      25.580 to 25.601 mm (1.00708 to 1.00791 in.)
      Maximum Inside Diameter
      25.601 mm (1.00791 in.)

      If the inside diameter is greater than the maximum, replace the rear planetary sun gear assembly.

  6. INSPECT FRONT PLANETARY GEAR ASSEMBLY


    1. B007ZZON02

      Using a feeler gauge, measure the clearance between the front 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 0.0260 in.)

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

  7. INSPECT UNDERDRIVE PLANETARY GEAR ASSEMBLY


    1. B005ONT

      Using a feeler gauge, measure the clearance between the underdrive planetary gear case and each pinion gear.

      Standard Clearance
      0.18 to 0.54 mm (0.00709 to 0.0213 in.)

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

  8. INSPECT ONE-WAY CLUTCH ASSEMBLY


    1. B007X8KC06
      *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.

  9. INSPECT NO. 1 BRAKE DISC


    1. B005MS4

      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 off or discolored, or even if part of the 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.

  10. INSPECT NO. 2 BRAKE DISC


    1. B005MP0

      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 off or discolored, or even if part of the groove is damaged, replace all of the No. 2 brake discs.

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

  11. INSPECT NO. 3 BRAKE DISC


    1. B005MS4

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

      If necessary, replace them.

      Note


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

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

  12. INSPECT NO. 1 CLUTCH DISC


    1. B005M4V

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

      If necessary, replace them.

      Note


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

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

  13. INSPECT NO. 2 CLUTCH DISC


    1. B005NVG

      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 off or discolored, or even if part of the groove is damaged, replace all of the No. 2 clutch discs.

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

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

    B005LFT

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

      Standard Free Length
      15.79 mm (0.622 in.)

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

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


    1. B005PZG

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

      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 sub-assembly.

  16. INSPECT CLEARANCE OF NO. 1 BRAKE PISTON


    1. B00804EC01
      *1 No. 1 Brake Piston
      *a Clearance

      Apply compressed air to the oil hole shown in the illustration, and check the operation of the No. 1 brake piston.

    2. Set a dial indicator as shown in the illustration.

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

      Standard Clearance
      0.400 to 0.600 mm (0.0157 to 0.0236 in.)

      Tech Tips

      Measure the clearance at 3 points where the No. 1 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 7 No. 1 brake flanges of different thicknesses.

      No. 1 Brake Flange Thickness
      Part No. Mark Thickness (mm (in.))
      35676-33020 30 3.0 (0.118)
      35676-33030 31 3.1 (0.122)
      35676-33040 32 3.2 (0.126)
      35676-33050 33 3.3 (0.130)
      35676-33060 34 3.4 (0.134)
      35676-33070 35 3.5 (0.138)
      35676-33080 36 3.6 (0.142)

  17. INSPECT CLEARANCE OF NO. 2 BRAKE PISTON


    1. B007X6NC01
      *1 No. 2 Brake Piston
      *a Clearance

      Apply compressed air to the oil hole shown in the illustration, and check the operation of the No. 2 brake piston.

    2. Set a dial indicator as shown in the illustration.

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

      Standard Clearance
      0.500 to 0.700 mm (0.0197 to 0.0276 in.)

      Tech Tips

      Measure the clearance at 3 points where the No. 2 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 9 No. 2 brake flanges of different thicknesses.

      No. 2 Brake Flange Thickness
      Part No. Mark Thickness (mm (in.))
      35678-78010 36 3.6 (0.142)
      35678-78020 37 3.7 (0.146)
      35678-78030 38 3.8 (0.150)
      35678-78040 39 3.9 (0.154)
      35678-33060 40 4.0 (0.157)
      35678-33070 41 4.1 (0.161)
      35678-33080 42 4.2 (0.165)
      35678-33090 43 4.3 (0.169)
      35678-33100 44 4.4 (0.173)

  18. INSPECT CLEARANCE OF NO. 3 BRAKE PISTON


    1. Using a vernier caliper and a straightedge, measure the distance shown in the illustration (Dimension (A)) while a load of 75 N (8 kgf, 16.9 lbf) is being applied to the No. 3 brake flange.

      B007ZIJC01
      *1 Front Oil Pump Assembly *2 No. 3 Brake Piston
      *3 No. 3 Brake Flange - -
      *a Dimension (A) *b Dimension (B)
      *c Contact Surface of Front Oil Pump Assembly - -

      Tech Tips

      Measure the distance (Dimension (A)) at 3 points where the No. 3 brake 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 the distance (Dimension (B)) at 3 points where the No. 3 brake piston 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
      0.300 to 0.500 mm (0.0118 to 0.0197 in.)

      If the clearance is not as specified, select an appropriate No. 3 brake flange so that the clearance will be within the specified range.

    4. Adjust clearance of No. 3 brake piston:


      1. B007ZLEC01
        *a Protective Tape

        Using a screwdriver with its tip wrapped with protective tape, remove the snap ring from the front oil pump assembly.

      2. B007WT8C01
        *1 No. 3 Brake Flange

        Remove the No. 3 brake flange from the front oil pump assembly.

      3. Using a vernier caliper and a straightedge, measure the distance shown in the illustration (Dimension (A)) while a load of 75 N (8 kgf, 16.9 lbf) is being applied to the No. 3 brake flange.

        B007YEUC01
        *1 Front Oil Pump Assembly *2 No. 3 Brake Piston
        *3 No. 3 Brake Disc - -
        *a Dimension (A) *b Dimension (B)
        *c Contact Surface of Front Oil Pump Assembly - -

        Tech Tips

        Measure the distance (Dimension (A)) at 3 points where the No. 3 brake disc diameter is approximately 166 mm (6.54 in.) and calculate the average.

      4. Using a vernier caliper and a straightedge, measure the distance shown in the illustration (Dimension (B)).

        Tech Tips

        Measure the distance (Dimension (B)) at 3 points where the No. 3 brake piston diameter is approximately 166 mm (6.54 in.) and calculate the average.

      5. Calculate the thickness of the replacement No. 3 brake flange using the following formula:

        Thickness of Replacement No. 3 Brake Flange
        Dimension (B) - Dimension (A) - (0.300 to 0.500 mm (0.0118 to 0.0197 in.))

        Tech Tips

        There are 8 No. 3 brake flanges of different thicknesses.

        No. 3 Brake Flange Thickness
        Part No. Mark Thickness (mm (in.))
        35679-73020 38 3.8 (0.150)
        35679-73030 39 3.9 (0.154)
        35679-73040 40 4.0 (0.157)
        35679-73050 41 4.1 (0.161)
        35679-73060 42 4.2 (0.165)
        35679-73070 43 4.3 (0.169)
        35679-73080 44 4.4 (0.173)
        35679-73090 45 4.5 (0.177)
      6. B007WT8C01
        *1 No. 3 Brake Flange

        Install the No. 3 brake flange to the front oil pump assembly.

      7. B007ZPSN07

        Using a screwdriver with its tip wrapped with protective tape, install the snap ring to the front oil pump assembly.

        Note


        • Confirm that the snap ring is correctly located in the groove of the front oil pump assembly.

        • Make sure that the snap ring ends are positioned as shown in the illustration (A).

  19. INSPECT CLEARANCE OF NO. 1 CLUTCH DISC


    1. B005LZJ

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

    2. Check that the piston moves when compressed air (200 kPa, 2.0 kgf/cm2, 29 psi) is applied to the oil hole.

    3. 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).

      Standard Pack Clearance
      0.806 to 0.974 mm (0.0317 to 0.0383 in.)

      Tech Tips

      Measure the clearance at 3 points where the No. 1 clutch flange diameter is approximately 152 mm (5.98 in.) and calculate the average.

      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 6 No. 1 clutch flanges of different thicknesses.

      No. 1 Clutch Flange Thickness: mm (in.)
      Part No. Mark Thickness
      35635-73010 30 3.0 (0.118)
      35635-73020 31 3.1 (0.122)
      35635-73030 32 3.2 (0.126)
      35635-73040 33 3.3 (0.130)
      35635-73050 34 3.4 (0.134)
      35635-73060 35 3.5 (0.138)

  20. INSPECT CLEARANCE OF NO. 2 CLUTCH DISC


    1. B005PLB

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

    2. Check that the piston moves when compressed air (200 kPa, 2.0 kgf/cm2, 29 psi) is applied to the oil hole.

    3. 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).

      Standard Pack Clearance
      0.544 to 0.744 mm (0.0214 to 0.0293 in.)

      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.

      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 6 No. 2 clutch flanges of different thicknesses.

      No. 2 Clutch Flange Thickness: mm (in.)
      Part No. Mark Thickness
      35635-73010 30 3.0 (0.118)
      35635-73020 31 3.1 (0.122)
      35635-73030 32 3.2 (0.126)
      35635-73040 33 3.3 (0.130)
      35635-73050 34 3.4 (0.134)
      35635-73060 35 3.5 (0.138)