AUTOMATIC TRANSMISSION UNIT > INSPECTION

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


    D029830

  1. Using vernier calipers, measure the free length of the spring together with the spring seat.

    Standard free length:
    23.74 mm (0.935 in.)

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



2. INSPECT REAR PLANETARY GEAR ASSEMBLY


    C109349

  1. Using a feeler gauge, measure the rear planetary gear pinion thrust clearance.

    Standard clearance:
    0.2 to 0.6 mm (0.008 to 0.024 in.)

    If the clearance is greater than the standard clearance, replace the planetary gear assembly.



    C109350

  1. Using a dial indicator, measure the inside diameter of the rear planetary gear bushing.

    Standard inside diameter:
    18.025 mm (0.710 in.)

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



3. INSPECT PACK CLEARANCE OF 1ST AND REVERSE BRAKE


    C108596

  1. Make sure that the 1st and reverse brake piston moves smoothly while applying compressed air intermittently into the transmission case.



    C108594E01

  1. Using vernier calipers, measure the level difference (length A) between the upper surface of the brake apply tube and the hitting surface of the brake flange No.4 at both ends across the 1st and reverse brake piston diameter, and calculate the average.

    NOTICE:
    The 1st and reverse brake piston must be securely installed to the end face of the transmission case.

    HINT:
    Length A = 23.32 to 24.18 mm (0.9181 to 0.952 in.)



    C108595E01

  1. Using vernier calipers, measure the combined thickness (length B) of the brake flanges, the 4 brake plates No.4 and the 5 brake discs No.4 at both ends across the diameter, and calculate the average.

    HINT:
    Length B = 23.64 to 26.00 mm (0.9303 to 1.0236 in.)
    Pack Clearance = Length A - Length B - 0.18 mm (0.0071 in.) + 1.8 mm (0.071 in.)

    Pack Clearance:
    0.5 to 0.8 mm (0.0197 to 0.0315 in.)

  1. If the pack clearance is outside the standard, select and install a brake flange that brings the pack clearance to be within the standard.

    HINT:
    There are 8 types of flanges that can be used to adjust the pack clearance. Select the one with the most appropriate thickness.

    Thickness H:
    NO.
    		Thickness H
    		NO.
    		Thickness H
    0
    		0 mm (0 in.)
    		8
    		0.8 mm (0.03150 in.)
    2
    		0.2 mm (0.00787 in.)
    		10
    		1.0 mm (0.03937 in.)
    4
    		0.4 mm (0.01575 in.)
    		12
    		1.2 mm (0.04724 in.)
    6
    		0.6 mm (0.02362 in.)
    		14
    		1.4 mm (0.05512 in.)



4. INSPECT BRAKE DISC NO.4


    D001216

  1. Check whether the sliding surfaces of the discs, the plates, and the flanges are worn or burnt.
    If necessary, replace them.

    NOTICE:
    1. If the linings of the discs are peeled off or discolored, or if any part of the printed numbers is damaged, replace all discs.
    2. Before assembling new discs, soak them in ATF for at least 15 minutes.



5. INSPECT INTERMEDIATE SHAFT


    D028529

  1. Using a dial indicator, check the intermediate shaft runout.

    Standard runout:
    0.03mm (0.0012 in.)

    If the runout exceeds the specification, replace the intermediate shaft with a new one.



    D028530E02

  1. Using a micrometer, check the outer diameter of the intermediate shaft at each point shown in the illustration.

    Standard diameter:
    A:
    22.962 to 22.975 mm (0.904 to 0.905 in.)
    B:
    22.962 to 22.975 mm (0.904 to 0.905 in.)
    C:
    27.759 to 27.775 mm (1.0929 to 1.0935 in.)
    D:
    27.759 to 27.775 mm (1.0929 to 1.0935 in.)

    If the outer diameter is outside the standard, replace the intermediate shaft a the new one.



6. INSPECT 1 WAY NO.3 CLUTCH ASSEMBLY


    D028532

  1. Hold the rear planetary ring gear flange sub-assembly and turn the 1 way clutch assembly.

  1. Check that the 1 way clutch assembly turns freely counterclockwise and locks clockwise.
    If there is a problem with the 1 way clutch, replace it.



7. INSPECT CENTER PLANETARY GEAR ASSEMBLY


    D028533

  1. Using a feeler gauge, measure the center planetary gear pinion thrust clearance.

    Standard clearance:
    0.12 to 0.68 mm (0.005 to 0.027 in.)

    If the clearance is greater than the standard clearance, replace the center planetary gear assembly.



8. INSPECT BRAKE DISC NO.2


    D001216

  1. Check whether the sliding surfaces of the discs, the plates, and the flange are worn or burnt.
    If necessary, replace them.

    NOTICE:
    1. If the linings of the discs are peeled off or discolored, or if any part of the printed numbers is damaged, replace all discs.
    2. Before assembling new discs, soak them in ATF for at least 15 minutes.



9. INSPECT BRAKE PISTON RETURN SPRING SUB-ASSEMBLY NO.2


    D029829

  1. Using vernier calipers, measure the free length of the spring together with the spring seat.

    Standard free length:
    22.66 mm (0.8921 in.)

    If the free length is shorter than the standard free length, replace the brake piston return spring sub-assembly No.2.



10. INSPECT PISTON STROKE OF BRAKE PISTON NO.2


  1. Inspect the piston stroke of the brake piston No.2.



      D031408

    1. Make sure that the brake piston No.2 moves smoothly while applying compressed air intermittently into the transmission case.



      2. C108592E01

    2. Using SST and a dial indicator, measure the moving distance (distance A) of the clutch disc at both ends across the diameter while blowing air from the oil hole as shown in the illustration, and calculate the average.

      SST
      09350-30020   (09350-06120)

      Pack Clearance:
      0.6 to 0.9 mm (0.024 to 0.035 in.)

    3. If the piston stroke is outside the standard, select and install a brake flange that brings the piston stroke within the standard.

      HINT:
      There are 8 types of flanges that can be used to adjust the pack clearance. Select one with the most appropriate thickness.

      Flange thickness:
      No.
      		Thickness
      0
      		2.0 mm (0.079 in.)
      1
      		2.1 mm (0.083 in.)
      2
      		2.2 mm (0.087 in.)
      3
      		2.3 mm (0.091 in.)
      4
      		2.4 mm (0.094 in.)
      5
      		2.5 mm (0.098 in.)
      6
      		2.6 mm (0.102 in.)
      7
      		2.7 mm (0.106 in.)



11. INSPECT BRAKE PISTON RETURN SPRING SUB-ASSEMBLY


    D003830

  1. Using vernier calipers, measure the free length of the spring together with the spring seat.

    Standard free length:
    17.05 mm (0.671 in.)

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



12. INSPECT FRONT PLANETARY GEAR ASSEMBLY


    D028544

  1. Using a feeler gauge, measure the front planetary pinion gear thrust clearance.

    Standard clearance:
    0.20 to 0.60 mm (0.008 to 0.024 in.)

    If the clearance is greater than the standard clearance, replace the front planetary gear assembly.



    D028543

  1. Using a dial indicator, measure the inside diameter of the front planetary gear bushing.

    Standard inside diameter:
    48.78 mm (1.9205 in.)

    If the inside diameter is greater than the standard inside diameter, replace the front planetary gear assembly.



13. INSPECT 1 WAY CLUTCH ASSEMBLY


    D028542

  1. Install the 1 way clutch assembly to the 1 way clutch inner race.

  1. Hold the 1 way clutch inner race and turn the 1 way clutch assembly.

  1. Check that the 1 way clutch assembly turns freely counterclockwise and locks clockwise.
    If there is a problem with the 1 way clutch, replace it.

  1. Remove the 1 way clutch assembly from the 1 way clutch inner race.



14. INSPECT PISTON STROKE OF BRAKE PISTON NO.1


  1. Inspect the piston stroke of brake piston No.1.



      D028814

    1. Make sure the brake piston No.1 moves smoothly while applying compressed air intermittently into the transmission case.



      2. D031407E01

    2. Using vernier calipers, measure the level difference (length A) between the upper surface of the brake piston No.1 and the hitting surface of the brake flange No.1 at both ends across the brake piston No.1 diameter.

    3. Using vernier calipers, measure the thickness (length B) of the brake flange, the 3 brake plates No.1 and the 3 brake discs No.1 altogether at both ends across the diameter, and calculate the average.

      HINT:
      Length A = 15.27 to 15.92 mm (0.60118 to 0.62677 in.)
      Length B = 14.50 to 15.54 mm (0.57087 to 0.691181 in.)
      Piston stroke = Length A - Length B

      Piston stroke:
      0.42 to 0.72 mm (0.017 to 0.028 in.)

      If the piston stroke is outside the specification, parts may have been assembled incorrectly, so check and reassemble again.
      If the piston stroke not still outside the specification range, select another flange that brings the piston stroke within the specification.

      HINT:
      There are 4 different thicknesses for the flange.

      Flange thickness:
      No.
      		Thickness
      0
      		2.0 mm (0.079 in.)
      1
      		2.2 mm (0.087 in.)
      2
      		2.4 mm (0.094 in.)
      3
      		2.6 mm (0.102 in.)



15. INSPECT BRAKE DISC NO.1


    D001216

  1. Check whether the sliding surfaces of the discs, the plates, or the flange are worn or burnt.
    If necessary, replace them.

    NOTICE:
    1. If the linings of the discs are peeled off or discolored, or if any part of the groove is damaged, replace all discs.
    2. Before assembling new discs, soak them in ATF for at least 15 minutes.



16. INSPECT 2ND BRAKE DISC SET


    D001216

  1. Check whether the sliding surfaces of the discs, the plates, or the flange are worn or burnt.
    If necessary, replace them.

    NOTICE:
    1. If the linings of the discs are peeled off or discolored, or if any part of the printed numbers is damaged, replace all discs.
    2. Before assembling new discs, soak them in ATF for at least 15 minutes.



17. INSPECT 1 WAY NO.2 CLUTCH ASSEMBLY


    D027993

  1. Hold the reverse clutch hub and turn the 1 way No.2 clutch assembly.

  1. Check that the 1 way No.2 clutch assembly turns freely clockwise and locks counterclockwise.
    If there is a problem with the 1 way clutch, replace it.



18. INSPECT INDIVIDUAL PISTON OPERATION


    C108591E01

  1. Check the operating sound while applying compressed air into the oil holes indicated in the illustration.

    HINT:
    When inspecting the O/D direct clutch, check with the C3 accumulator piston hole closed.
    If there is no sound, disassemble and check the parts installation condition.


    1. Clutch No.2 (C2)

    2. Clutch No.4 (C4)

    3. Clutch No.3 (C3)

    4. Clutch No.1 (C1)

    5. Brake No.3 (B3)

    6. Brake No.1 (B1)

    7. Brake No.2 (B2)

    8. Brake No.4 (B4)