Automatic Transaxle Unit: Inspection

INSPECT AUTOMATIC TRANSAXLE OIL PAN SUB-ASSEMBLY
1. Remove the 2 oil cleaner magnets and use them to collect any steel chips. Carefully examine the chips and particles in the pan and on the magnet to determine what type of wear has occurred in the transaxle:
  Steel (magnetic)...bearing, gear and plate wear
  
  Brass (non-magnetic)...bushing wear
  
  Fig 1: Collecting Steel Chips Using Magnet
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT PISTON STROKE OF 2ND COAST BRAKE
1. Apply a small amount of paint to the piston rod at the point where it meets the case.
  
  Fig 2: Applying Small Amount Of Paint To Piston Rod
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using SST, measure the piston stroke while applying and releasing compressed air (392 to 785 kPa, 4 to 8 kgf/² , 57 to 114 psi).
  SST 09240-00020
  
  Piston stroke:
  
  1.5 to 3.0 mm (0.059 to 0.118 in.)
  
  If the piston stroke exceeds the limit, inspect the brake band.
  
  Fig 3: Measuring Piston Stroke
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT 2ND COAST BRAKE BAND ASSEMBLY
1. If the lining of the 2nd coast brake band assembly is peeling off or discolored, or even if a part of the printed numbers are defaced, replace the 2nd coast brake band assembly.
  
  Fig 4: Identifying Printed Number Location On 2nd Coast Brake Band Assembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT FRONT PLANETARY GEAR ASSEMBLY
1. Using a feeler gauge, measure the planetary pinion gear thrust clearance.
  Standard clearance:
  
  0.2 to 0.5 mm (0.008 to 0.020 in.)
  
  Maximum clearance:
  
  0.55 mm (0.022 in.)
  
  If the clearance is greater than the maximum, replace the front planetary gear assembly.
  
  Fig 5: Measuring Planetary Pinion Gear Thrust Clearance
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT 1 WAY CLUTCH ASSEMBLY
1. Hold the sun gear and turn the hub. The hub should turn freely clockwise and should lock if turned counterclockwise.
  
  Fig 6: Inspecting 1 Way Clutch Assembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT 2ND BRAKE PISTON
1. Using compressed air, check that the 2nd brake piston moves smoothly.
  
  Fig 7: Inspecting 2nd Brake Piston
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT 2ND BRAKE CLUTCH DISC
1. Check if the sliding surfaces of the discs, plates and flanges are worn or burnt. If necessary, replace them.
  HINT:
  - If the lining of the disc is peeling off or discolored, even if a part of the printed numbers are defaced, replace all discs.
  - Before assembling new discs, soak them in ATF for at least 15 minutes.
    
    Fig 8: Identifying Printed Number Location On 2nd Brake Clutch Disc
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT REAR PLANETARY GEAR ASSEMBLY
1. Using a feeler gauge, measure the planetary pinion gear thrust clearance.
  Standard clearance:
  
  0.2 to 0.5 mm (0.008 to 0.020 in.)
  
  Maximum clearance:
  
  0.55 mm (0.022 in.)
  
  If the clearance is greater than maximum, replace the rear planetary gear assembly.
  
  Fig 9: Measuring Planetary Pinion Gear Thrust Clearance
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT PACK CLEARANCE OF FIRST AND REVERSE BRAKE
1. Using a feeler gauge, measure the first & reverse brake pack clearance.
  Pack clearance:
  
  1.19 to 2.25 mm (0.0469 to 0.0886 in.)
  
  If the pack clearance is non-standard, check the disc.
  
  Fig 10: Measuring First And Reverse Brake Pack Clearance
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT 1ST AND REVERSE BRAKE CLUTCH DISC
1. Check if the sliding surfaces of the discs, plates and flanges are worn or burnt. If necessary, replace them.
  HINT:
  - If the lining of the disc is peeling off or discolored, even if a part of the printed numbers are defaced, replace all discs.
  - Before assembling new discs, soak them in ATF for at least 15 minutes.
    
    Fig 11: Identifying Printed Number Location On 1st And Reverse Brake Clutch Disc
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

INSPECT PISTON STROKE OF UNDERDRIVE CLUTCH

Set a dial indicator (long type pick or SST).
SST 09350-32014 (09351-32190)

Fig 12: Setting Dial Indicator
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
While applying and releasing compressed air (392 to 785 kPa, 4 to 8 kgf/² , 57 to 114 psi), measure the underdrive clutch piston stroke.
Piston stroke:

1.5 to 1.9 mm (0.059 to 0.075 in.)

Fig 13: Measuring Underdrive Clutch Piston Stroke
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

If the piston stroke is non-standard, select another flange.

HINT:

There are 4 different flange thickness.

Flange thickness:

mm (in.)

THICKNESS CHART

Thickness	Thickness
2.04 (0.0803)	2.40 (0.0945)
2.20 (0.0866)	2.50 (0.0984)

INSPECT UNDERDRIVE 1 WAY CLUTCH ASSEMBLY
1. Hold the 1 way clutch drum and turn the 1 way clutch. Check that the 1 way clutch must be able to turn free counterclockwise and will lock if turned clockwise.
  
  Fig 14: Inspecting Underdrive 1 Way Clutch Assembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT PACK CLEARANCE OF UNDERDRIVE BRAKE
1. Using a dial indicator, measure the underdrive brake pack clearance.
  Pack clearance:
  
  1.15 to 1.97 mm (0.0453 to 0.0786 in.)
  
  If clearance is non-standard, check the disc.
  
  Fig 15: Inspecting Pack Clearance Of Underdrive Brake
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT UNDERDRIVE CLUTCH DISC NO.2
1. Check if the sliding surfaces of the discs, plates and flanges are worn or burnt. If necessary, replace them.
  HINT:
  - If the lining of the disc is peeling off or discolored, even if a part of the printed numbers are defaced, replace all discs.
  - Before assembling new discs, soak them in ATF for at least 15 minutes.
    
    Fig 16: Identifying Printed Number Location On Underdrive Clutch Disc
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT HEIGHT OF CLUTCH ASSEMBLY
1. Using vernier calipers, check the height from the sleeve to the inner race.
  Height:
  
  17.3 to 18.2 mm (0.681 to 0.717 in.)
  
  Fig 17: Checking Height Of Clutch Assembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

INSPECT PISTON STROKE OF UNDERDRIVE CLUTCH

Set a dial indicator and measuring terminal (SST) together.
SST 09350-32014 (09351-32190)

Fig 18: Setting Dial Indicator
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

While applying and releasing compressed air (392 to 785 CPS, 4 to 8 kgf/² , 57 to 114 psi), measure the underdrive clutch piston stroke.

Piston stroke:

1.5 to 1.9 mm (0.059 to 0.075 in.)

If the piston stroke is less than the limit, parts may have been misassembled. Check them. If the piston stroke is non-standard, select another flange.

HINT:

There are 4 different thickness for the flange.

Flange thickness:

mm (in.)

Fig 19: Inspecting Piston Stroke Of Underdrive Clutch

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

THICKNESS CHART

Thickness	Thickness
2.04 (0.0803)	2.40 (0.0945)
2.20 (0.0866)	2.50 (0.0984)

INSPECT HEIGHT OF COUNTER SHAFT
1. Using vernier calipers, measure the distance between the tip of the counter shaft and bolt seat of the clutch support.
  Height:
  
  30.3 to 32.5 mm (1.193 to 1.280 in.)
  
  Fig 20: Measuring Distance Between Tip Of Counter Shaft And Clutch Support Bolt Seat
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT DRIVE GEAR PRELOAD
1. Using a torque wrench, measure the starting torque of the counter drive gear.
  Torque: Starting torque
  
  0.11 to 0.70 N*m (1.1 to 7.1 kgf*cm, 0.9 to 6.1 in.*lbf)
  
  Rotating torque
  
  0.04 to 0.30 N*m (0.4 to 3.0 kgf*cm, 0.3 to 2.6 in.*lbf)
  
  If the torque exceeds the limit, replace the spacer.
  
  Fig 21: Measuring Starting Torque Of Counter Drive Gear
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT END PLAY OF COUNTER SHAFT
1. Using a dial indicator, measure the end play of the counter shaft.
  End play:
  
  0.2 to 0.9 mm (0.008 to 0.035 in.)
  
  Fig 22: Measuring End Play Of Counter Shaft
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT INTERMEDIATE SHAFT SUB-ASSEMBLY
1. Make sure that the intermediate shaft sub-assembly turns smoothly.
  
  Fig 23: Inspecting Intermediate Shaft Sub-Assembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT PACK CLEARANCE OF FIRST AND REVERSE BRAKE
1. Using a feeler gauge, measure the first & reverse brake pack clearance.
  Pack clearance:
  
  1.19 to 2.25 mm (0.0469 to 0.0886 in.)
  
  If the pack clearance is non-standard, parts have been misassembled. Check them.
  
  Fig 24: Measuring First And Reverse Brake Pack Clearance
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT 2ND BRAKE PISTON
1. Using compressed air, check that the 2nd brake piston moves smoothly.
  
  Fig 25: Inspecting 2nd Brake Piston
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT 2ND BRAKE HUB INSTALLATION DISTANCE
1. Check the distance between the surface of the 2nd brake hub and rear planetary gear.
  Distance:
  
  Approx. 5 mm (0.20 in.)
  
  Fig 26: Checking Distance Between Surface Of 2nd Brake Hub And Rear Planetary Gear
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT PISTON STROKE OF 2ND COAST BRAKE
1. Apply a small amount of paint to the piston rod at the point where it meets the case.
  
  Fig 27: Applying Small Amount Of Paint To Piston Rod
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using SST, measure the piston stroke while applying and releasing compressed air (392 to 785 kPa, 4 to 8 kgf/² , 57 to 114 psi).
  SST 09240-00020
  
  Piston stroke:
  
  1.5 to 3.0 mm (0.059 to 0.118 in.)
  
  If the piston stroke exceeds the limit, select a new piston rod.
  
  Fig 28: Measuring Piston Stroke Of 2nd Coast Brake
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

INSPECT INPUT SHAFT ASSEMBLY

Measure the thrust play in the axial direction.

Thrust play:

0.3 to 0.9 mm (0.012 to 0.035 in.)

If the play is not as specified, select and replace the race for the end of the input shaft assembly.

HINT:

There are 3 different thickness for races, if necessary, select one of them.

Race thickness:

mm (in.)

Fig 29: Measuring Input Shaft Thrust Play

THICKNESS CHART

Thickness	Thickness
0.8 (0.031)	1.0 (0.039)
1.4 (0.055)	-

INSPECT INPUT SHAFT ENDPLAY
1. Make sure that the input shaft rotates smoothly.
  
  Fig 30: Inspecting Input Shaft
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002