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Inspection [09/2014 - ]: Procedure

WARNING: This page is about a different variant/trim than selected.
  1. INSPECT 1ST AND REVERSE BRAKE RETURN SPRING SUB-ASSEMBLY 
    1. Using a vernier caliper, measure the free length of the 1st and reverse brake return spring sub-assembly including the spring seat.
      GTY468990Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Standard Free Length

      23.74 mm (0.935 in.)

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

  2. INSPECT REAR PLANETARY GEAR ASSEMBLY 
    1. Using a feeler gauge, measure the clearance between the rear planetary gear assembly and each pinion gear.
      GTY458249Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Standard Clearance

      0.2 to 0.6 mm (0.00788 to 0.0236 in.)

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

    2. Using a caliper gauge, measure the inside diameter of the rear planetary gear bushing.
      GTY458251Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Standard Inside Diameter

      20.025 mm (0.788 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 PISTON 
    1. Check that the 1st and reverse brake piston moves smoothly when applying and releasing compressed air (392 kPa, 4.0 kgf/cm2 , 57 psi).
      GTY457815Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      If the 1st and reverse brake piston does not move smoothly, check the 1st and reverse brake piston, O-ring and oil paths of the automatic transmission case sub-assembly.

    2. Using a vernier caliper, measure the distance between the brake apply tube and contact surface of the No. 4 brake flange (Dimension (A)) at several points, and calculate the average.
      GTY467342Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:

      The 1st and reverse brake piston must be installed securely to the automatic transmission case sub-assembly.

      HINT: 

      Dimension (A) = 22.05 to 22.91 mm (0.869 to 0.901 in.)

    3. Using a vernier caliper, measure the thickness of the No. 4 brake flange, 4 No. 4 brake plates and 4 No. 4 brake discs (Dimension B) at several points while applying 4.9 N (0.5 kgf, 1.1 lbf) or less of pressure, and calculate the average.

      HINT: 

      Dimension (B) = 23.11 to 23.89 mm (0.910 to 0.941 in.)

      Pack Clearance = Dimension (A) - Dimension (B) - 0.22 mm (0.00866 in.) + 1.8 mm (0.0709 in.)

      Standard Clearance

      0.4 to 0.7 mm (0.0158 to 0.0275 in.)

      GTY457683Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      If the pack clearance is not within the specified range, select and install an appropriate No. 4 brake flange that will bring the pack clearance within the specified range.

      HINT: 

      There are 11 No. 4 brake flanges of different thicknesses.

      Thickness H

      Part No. Mark Thickness (H)
      35689-60270 0 0 mm (0 in.)
      35689-60280 1 0.17 mm
      (0.00669 in.)
      35689-60290 3 0.31 mm
      (0.0122 in.)
      35689-60300 4 0.45 mm
      (0.0177 in.)
      35689-60310 5 0.59 mm
      (0.0232 in.)
      35689-60320 7 0.73 mm
      (0.0287 in.)
      35689-60330 8 0.87 mm
      (0.0343 in.)
      35689-60340 10 1.01 mm
      (0.0398 in.)
      35689-60350 11 1.15 mm
      (0.0453 in.)
      35689-60360 12 1.29 mm
      (0.0508 in.)
      35689-60370 14 1.43 mm
      (0.0563 in.)
  4. INSPECT NO. 4 BRAKE DISC 
    1. Check if the contact surfaces of the No. 4 brake discs, No. 4 brake plates or No. 4 brake flange are worn or burnt. If necessary, replace them.
      GTY457910Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:
      • If the lining of any No. 4 brake disc is peeled or discolored, or even if part of the printed number is damaged, replace all No. 4 brake discs.
      • Before installing new No. 4 brake discs, soak them in ATF for at least 15 minutes.
  5. INSPECT INTERMEDIATE SHAFT 
    1. Using a dial indicator, check the runout of the intermediate shaft.
      GTY457842Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Maximum Runout

      0.03 mm (0.00118 in.)

      If the runout exceeds the maximum, replace the intermediate shaft.

    2. Using a micrometer, check the outer diameter of the intermediate shaft at each point shown in the illustration.
      GTY467037Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Standard Diameter

      Part (A):

      25.962 to 25.975 mm (1.02212 to 1.02264 in.)

      Part (B):

      32.062 to 32.075 mm (1.26228 to 1.26279 in.)

      If the outer diameter is not within the specified range, replace the intermediate shaft.

  6. INSPECT REAR PLANETARY RING GEAR FLANGE SUB-ASSEMBLY 
    1. Using a caliper gauge, measure the inside diameter of the rear planetary ring gear bushing.
      GTY468898Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Standard Inside Diameter

      32.19 mm (1.27 in.)

      If the inside diameter is greater than the standard inside diameter, replace the rear planetary ring gear flange sub-assembly.

  7. INSPECT NO. 3 ONE-WAY CLUTCH ASSEMBLY 
    1. Hold the rear planetary ring gear flange sub-assembly and turn the No. 3 one-way clutch assembly.
    2. Check that the No. 3 one-way clutch assembly turns freely counterclockwise and locks when turned clockwise.

      If the No. 3 one-way clutch assembly does not operate normally, replace it.

      GTY462239Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Lock
      Free
  8. INSPECT CENTER PLANETARY GEAR ASSEMBLY 
    1. Using a feeler gauge, measure the clearance between the center planetary gear assembly and each pinion gear.
      GTY468899Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Standard Clearance

      0.12 to 0.68 mm (0.00472 to 0.0267 in.)

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

  9. INSPECT NO. 2 BRAKE DISC 
    1. Check if the contact surfaces of the No. 2 brake discs, No. 2 brake plates or No. 2 brake flange are worn or burnt. If necessary, replace them.
      GTY457910Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      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 No. 2 brake discs.
      • Before installing new No. 2 brake discs, soak them in ATF for at least 15 minutes.
  10. INSPECT NO. 2 BRAKE PISTON RETURN SPRING SUB-ASSEMBLY 
    1. Using a vernier caliper, measure the free length of the No. 2 brake piston return spring sub-assembly including the spring seat.
      GTY458248Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Standard Free Length

      22.66 mm (0.892 in.)

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

  11. INSPECT NO. 2 BRAKE PISTON 
    1. Inspect the piston stroke of the No. 2 brake piston.
      1. Check that the No. 2 brake piston moves smoothly when applying and releasing compressed air (392 kPa, 4.0 kgf/cm2 , 57 psi).
        GTY458211Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

        If the No. 2 brake piston does not move smoothly, check the No. 2 brake piston, O-rings and oil paths of the automatic transmission case sub-assembly.

      2. Using SST and a dial indicator, measure the piston stroke of the No. 2 brake piston at several points while applying compressed air (392 kPa, 4.0 kgf/cm2 , 57 psi) to the oil hole as shown in the illustration, and calculate the average.
        GTY460735Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        • SST: 09350-30020 
          1. 09350-06120

        Piston Stroke

        0.6 to 0.9 mm (0.0237 to 0.0354 in.)

        If the piston stroke is not within the specified range, select and install a No. 2 brake flange that will bring the piston stroke within the specified range.

        HINT: 

        There are 8 No. 2 brake flanges of different thickness.

        Flange Thickness

        Part No. Mark Thickness
        35678-60020 0 2.0 mm
        (0.0787 in.)
        35678-60030 1 2.1 mm
        (0.0827 in.)
        35678-60040 2 2.2 mm
        (0.0866 in.)
        35678-60050 3 2.3 mm
        (0.0906 in.)
        35678-60060 4 2.4 mm
        (0.0945 in.)
        35678-60070 5 2.5 mm
        (0.0984 in.)
        35678-60080 6 2.6 mm
        (0.102 in.)
        35678-60090 7 2.7 mm
        (0.106 in.)
  12. INSPECT BRAKE PISTON RETURN SPRING SUB-ASSEMBLY 
    1. Using a vernier caliper, measure the free length of the brake piston return spring sub-assembly including the spring seat.
      GTY457825Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Standard Free Length

      17.05 mm (0.671 in.)

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

  13. INSPECT FRONT PLANETARY GEAR ASSEMBLY 
    1. GTY457851Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

      Standard Clearance

      0.2 to 0.6 mm (0.00788 to 0.0236 in.)

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

    2. Using a cylinder gauge, measure the inside diameter of the front planetary gear bushing.
      GTY457860Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Standard Inside Diameter

      57.43 mm (2.26 in.)

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

  14. INSPECT ONE-WAY CLUTCH ASSEMBLY 
    1. Install the one-way clutch assembly to the one-way clutch inner race.
    2. Hold the one-way clutch inner race and turn the one-way clutch assembly.
    3. Check that the one-way clutch assembly turns freely counterclockwise and locks when turned clockwise.
      GTY456149Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Lock
      Free

      If the one-way clutch assembly does not operate normally, replace it.

    4. Remove the one-way clutch assembly from the one-way clutch inner race.
  15. INSPECT NO. 1 BRAKE PISTON 
    1. Inspect the piston stroke of the No. 1 brake piston.
      1. Check that the No. 1 brake piston moves smoothly when applying and releasing compressed air (392 kPa, 4.0 kgf/cm2 , 57 psi).

        If the No. 1 brake piston does not move smoothly, check the No. 1 brake piston, O-rings and oil paths of the automatic transmission case sub-assembly.

        GTY457770Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      2. Using a vernier caliper, measure the distance (dimension (A)) between the No. 1 brake piston and the contact surface of the No. 1 brake flange at several points, while applying 4.9 N (0.5 kgf, 1.1 lbf) or less of pressure, and calculate the average.
        GTY465205Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      3. Using a vernier caliper, measure the thickness (dimension (B)) of the No. 1 brake flange, 3 No. 1 brake plates and 3 No. 1 brake discs at several points, while applying 4.9 N (0.5 kgf, 1.1 lbf) or less of pressure, and calculate the average.

        HINT: 

        Dimension (A) = 15.29 to 15.77 mm (0.602 to 0.621 in.)

        Dimension (B) = 14.72 to 15.12 mm (0.580 to 0.595 in.)

        Piston stroke = Dimension (A) - Dimension (B)

        Piston Stroke

        0.42 to 0.72 mm (0.0166 to 0.0283 in.)

        If the piston stroke is not within the specified range, parts may have been assembled incorrectly. Check and reassemble them.

        If the piston stroke is still out of specified range, select and install an appropriate No. 1 brake flange that will bring the piston stroke within the specified range.

        HINT: 

        There are 4 No. 1 brake flanges of different thicknesses.

        Flange Thickness

        Part No. Mark Thickness
        35676-60080 0 2.0 mm
        (0.0787 in.)
        35676-60090 1 2.2 mm
        (0.0866 in.)
        35676-60100 2 2.4 mm
        (0.0945 in.)
        35676-60110 3 2.6 mm
        (0.102 in.)
  16. INSPECT NO. 1 BRAKE DISC 
    1. Check if the contact surfaces of the No. 1 brake discs, No. 1 brake plates or No. 1 brake flange are worn or burnt. If necessary, replace them.
      GTY457910Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:
      • If the lining of any No. 1 brake disc is peeled or even discolored, or even if any part of the printed number is damaged, replace all No. 1 brake discs.
      • Before installing new No. 1 discs, soak them in ATF for at least 15 minutes.
  17. INSPECT NO. 3 BRAKE PISTON RETURN SPRING SUB-ASSEMBLY 
    1. Using a vernier caliper, measure the free length of the No. 3 brake piston return spring sub-assembly including the spring seat.
      GTY457775Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Standard Free Length

      15.72 mm (0.619 in.)

      If the free length is less than the standard free length, replace the No. 3 brake piston return spring sub-assembly.

  18. INSPECT NO. 3 BRAKE DISC 
    1. Check if the contact surfaces of the No. 3 brake discs, No. 3 brake plates or No. 3 brake flange are worn or burnt. If necessary, replace them.
      GTY457910Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:
      • If the lining of any No. 3 brake disc is peeled or discolored, or even if any part of the printed number is damaged, replace all No. 3 brake discs.
      • Before installing new No. 3 discs, soak them in ATF for at least 15 minutes.
  19. INSPECT NO. 2 ONE-WAY CLUTCH ASSEMBLY 
    1. Hold the reverse clutch hub and turn the No. 2 one-way clutch assembly.
    2. Check that the No. 2 one-way clutch assembly turns freely clockwise and locks when turned counterclockwise.

      If the No. 2 one-way clutch assembly does not operate normally, replace it.

      GTY467486Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Lock
      Free
  20. INSPECT INDIVIDUAL PISTON OPERATION 
    1. Check the operating sound of each piston while applying compressed air to each oil hole shown in the illustration.
      GTY510489Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a No. 1 Clutch Oil Hole
      *b No. 2 Clutch Oil Hole
      *c No. 3 Clutch Oil Hole
      *d No. 4 Clutch Oil Hole
      *e No. 1 Brake Oil Hole
      *f No. 2 Brake Oil Hole
      *g No. 3 Brake Oil Hole
      *f No. 4 Brake (In) Oil Hole
      *h No. 4 Brake (Out) Oil Hole

      HINT: 

      When inspecting the No. 2 direct clutch, cover the installation hole of the C3 accumulator piston.

      If no operating sounds can be heard, check the installation condition of the parts.

  21. INSPECT UNDERDRIVE ONE-WAY CLUTCH ASSEMBLY 
    1. Hold the coast clutch hub and turn the underdrive one-way clutch assembly.
    2. Check that the underdrive one-way clutch assembly turns freely clockwise and locks when turned counterclockwise.
      GTY458759Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Lock
      Free

      If the underdrive one-way clutch assembly does not operate normally, replace it.

  22. INSPECT DIRECT CLUTCH RETURN SPRING SUB-ASSEMBLY 
    1. Using a vernier caliper, measure the free length of the direct clutch return spring sub-assembly including the spring seat.
      GTY106454Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Standard Free Length

      19.51 mm (0.768 in.)

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

  23. INSPECT REVERSE CLUTCH RETURN SPRING SUB-ASSEMBLY 
    1. Using a vernier caliper, measure the free length of the reverse clutch return spring sub-assembly including the spring seat.
      GTY457902Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Standard Free Length

      21.04 mm (0.828 in.)

      If the free length is less than the standard free length, replace the reverse clutch return spring sub-assembly.

  24. INSPECT NO. 2 DIRECT CLUTCH DISC 
    1. Check if the contact surfaces of the No. 2 direct clutch discs, No. 2 clutch plates or reverse clutch flange are worn or burnt. If necessary, replace them.
      GTY457910Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:
      • If the lining of any No. 2 direct clutch disc is peeled or discolored, or even if any part of the printed number is damaged, replace all No. 2 direct clutch disc.
      • Before installing new No. 2 direct clutch discs, soak them in ATF for at least 15 minutes.
  25. INSPECT PACK CLEARANCE OF NO. 2 DIRECT CLUTCH 
    1. Inspect the clearance of the No. 2 direct clutch.
      GTY464820Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. Using a dial indicator, measure the moving distance (Dimension (A)) of the reverse clutch flange at several points while applying compressed air (392 kPa, 4.0 kgf/cm2 , 28 psi) to the oil hole as shown in the illustration, and calculate the average.

        HINT: 

        Dimension (A) = 0.36 to 1.24 mm (0.0142 to 0.0488 in.)

        Clearance = Dimension (A) - 0.05 mm (0.00197 in.)

        Standard Clearance

        0.5 to 0.8 mm (0.0197 to 0.0314 in.)

        NOTE:

        Install a standard flange (3.4 mm (0.1339 in.)) when measuring the flange moving distance (A).

        If the clearance is not within the specified range, select and install a reverse clutch flange that will bring the clearance within the specified range.

        HINT: 

        There are 9 reverse clutch flanges of different thickness.

        Reverse Clutch Flange Thickness

        Part No. Mark Thickness
        35649-60030 2 3.0 mm
        (0.118 in.)
        35649-60040 3 3.1 mm
        (0.122 in.)
        35649-60050 4 3.2 mm
        (0.126 in.)
        35649-60060 5 3.3 mm
        (0.130 in.)
        35649-60070 6 3.4 mm
        (0.134 in.)
        35649-60080 7 3.5 mm
        (0.138 in.)
        35649-60090 8 3.6 mm
        (0.142 in.)
        35649-60100 9 3.7 mm
        (0.146 in.)
        35649-60110 A 3.8 mm
        (0.150 in.)
  26. INSPECT PACK CLEARANCE OF NO. 3 CLUTCH 
    1. Inspect the clearance of the No. 3 clutch.
      1. Using a dial indicator, measure the reverse clutch piston stroke (Dimension (A)) and the moving distance (Dimension (B)) of the reverse clutch flange at several points while applying compressed air (392 kPa, 4.0 kgf/cm2 , 57 psi) to the oil hole as shown in the illustration, and calculate the average.
        GTY463122Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

        HINT: 

        Dimension (A) = 1.05 to 2.15 mm (0.0413 to 0.0846 in.)

        Dimension (B) = 0.72 to 1.08 mm (0.0283 to 0.0425 in.)

        Clearance = Dimension (A) - Dimension (B) - 0.06 mm (0.00236 in.)

        Standard Clearance

        0.5 to 0.8 mm (0.0197 to 0.0314 in.)

        NOTE:

        Install a standard flange (3.3 mm (0.130 in.)) when measuring the flange moving distance (B).

        If the clearance is not within the specified range, select and install a reverse clutch flange that will bring the clearance within the specified range.

        HINT: 

        There are 11 reverse clutch flanges of different thickness.

        Reverse Clutch Flange Thickness

        Part No. Mark Thickness
        35649-60010 0 2.8 mm
        (0.110 in.)
        35649-60020 1 2.9 mm
        (0.114 in.)
        35649-60030 2 3.0 mm
        (0.118 in.)
        35649-60040 3 3.1 mm
        (0.122 in.)
        35649-60050 4 3.2 mm
        (0.126 in.)
        35649-60060 5 3.3 mm
        (0.130 in.)
        35649-60070 6 3.4 mm
        (0.134 in.)
        35649-60080 7 3.5 mm
        (0.138 in.)
        35649-60090 8 3.6 mm
        (0.142 in.)
        35649-60100 9 3.7 mm
        (0.146 in.)
        35649-60110 A 3.8 mm
        (0.150 in.)
  27. INSPECT FORWARD CLUTCH RETURN SPRING SUB-ASSEMBLY 
    1. Using a vernier caliper, measure the free length of the forward clutch return spring sub-assembly including the spring seat.
      GTY457902Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Standard Free Length

      24.64 mm (0.970 in.)

      If the free length is less than the standard free length, replace the forward clutch return spring sub-assembly.

  28. INSPECT COAST CLUTCH DISC 
    1. Check if the contact surfaces of the coast clutch discs, coast clutch plates or reverse clutch flange are worn or burnt. If necessary, replace them.
      GTY457910Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:
      • If the lining of any coast clutch disc is peeled or discolored, or even if any part of the printed number is damaged, replace all coast clutch discs.
      • Before installing new coast clutch discs, soak them in ATF for at least 15 minutes.
  29. INSPECT PACK CLEARANCE OF COAST CLUTCH HUB SUB-ASSEMBLY 
    1. Inspect the clearance of the coast clutch hub sub-assembly.
      GTY464880Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. Using a dial indicator, measure the moving distance (Dimension (A)) of the reverse clutch flange at multiple points while applying compressed air (196 kPa, 2.0 kgf/cm2 , 28 psi) to the oil hole as shown in the illustration, and calculate the average.

        HINT: 

        Dimension (A) = 0.38 to 1.48 mm (0.0150 to 0.0582 in.)

        Clearance = Dimension (A) - 0.02 mm (0.000787 in.)

        Standard Clearance

        0.3 to 0.6 mm (0.0118 to 0.0236 in.)

        NOTE:

        Install a standard flange (3.0 mm (0.118 in.)) when measuring the flange moving distance (A).

        If the clearance is not within the specified range, select and install a reverse clutch flange that will bring the clearance within the specified range.

        HINT: 

        There are 10 reverse clutch flanges of different thickness.

        Reverse Clutch Flange Thickness

        Part No. Mark Thickness
        35675-50010 0 3.0 mm
        (0.118 in.)
        35675-50020 1 3.1 mm
        (0.122 in.)
        35675-50030 2 3.2 mm
        (0.126 in.)
        35675-50040 3 3.3 mm
        (0.130 in.)
        35675-50050 4 3.4 mm
        (0.134 in.)
        35675-50060 5 3.5 mm
        (0.138 in.)
        35675-50070 6 3.6 mm
        (0.142 in.)
        35675-50080 7 3.7 mm
        (0.146 in.)
        35675-50090 8 3.8 mm
        (0.150 in.)
        35675-50100 A 3.9 mm
        (0.154 in.)
  30. INSPECT NO. 1 CLUTCH DISC 
    1. Check if the contact surfaces of the No. 1 clutch discs, No. 1 clutch plates or No. 1 clutch flange are worn or burnt. If necessary, replace them.
      GTY457910Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:
      • If the lining of any No. 1 clutch disc is peeled or discolored, or even if any part of the printed number is damaged, replace all No. 1 clutch discs.
      • Before installing new No. 1 clutch discs, soak them in ATF for at least 15 minutes.
  31. INSPECT PACK CLEARANCE OF NO. 1 CLUTCH 
    1. Inspect the clearance of the No. 1 clutch.
      1. Using a dial indicator, measure the moving distance (Dimension (A)) of the forward clutch flange at multiple points while applying compressed air (196 kPa, 2.0 kgf/cm2 , 28 psi) to the oil hole as shown in the illustration, and calculate the average.
        GTY466826Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

        HINT: 

        Dimension (A) = 0.36 to 1.50 mm (0.0142 to 0.0591 in.)

        Clearance = Dimension (A) - 0.11 mm (0.00433 in.)

        Standard Clearance

        0.56 to 0.86 mm (0.0221 to 0.0338 in.)

        NOTE:

        Install a standard flange (3.4 mm (0.134 in.)) when measuring the flange moving distance (A).

        If the clearance is not within the specified range, select and install a reverse clutch flange that will bring the clearance within the specified range.

        HINT: 

        There are 11 forward clutch flanges of different thickness.

        Forward Clutch Flange Thickness

        Part No. Mark Thickness
        35635-60010 0 3.0 mm
        (0.118 in.)
        35635-60020 1 3.1 mm
        (0.122 in.)
        35635-60030 2 3.2 mm
        (0.126 in.)
        35635-60040 3 3.3 mm
        (0.130 in.)
        35635-60050 4 3.4 mm
        (0.134 in.)
        35635-60060 5 3.5 mm
        (0.138 in.)
        35635-60070 6 3.6 mm
        (0.142 in.)
        35635-60080 7 3.7 mm
        (0.146 in.)
        35635-60090 8 3.8 mm
        (0.150 in.)
        35635-60100 9 3.9 mm
        (0.154 in.)
        35635-60110 A 4.0 mm
        (0.158 in.)
  32. INSPECT FORWARD CLUTCH HUB SUB-ASSEMBLY 
    1. Using a caliper gauge, measure the inside diameter of the forward clutch hub bushing.
      GTY457880Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Standard Inside Diameter

      26.037 to 26.062 mm (1.02508 to 1.02606 in.)

      Maximum Inside Diameter

      26.062 mm (1.02606 in.)

      If the inside diameter is greater than the maximum inside diameter, replace the forward clutch hub sub-assembly.

  33. INSPECT NO. 3 CLUTCH DISC 
    1. Check if the contact surfaces of the No. 3 clutch discs, No. 3 clutch plates or reverse clutch flange are worn or burnt. If necessary, replace them.
      GTY457910Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:
      • If the lining of any No. 3 brake disc is peeled or discolored, or even if any part of the printed number is damaged, replace all No. 3 brake discs.
      • Before installing new No. 3 clutch discs, soak them in ATF for at least 15 minutes.
  34. INSPECT REVERSE CLUTCH HUB SUB-ASSEMBLY 
    1. Using a caliper gauge, measure the inside diameter of the reverse clutch hub bushing.
      GTY457866Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Standard Inside Diameter

      35.812 to 35.837 mm (1.40992 to 1.41090 in.)

      Maximum Inside Diameter

      35.837 mm (1.41090 in.)

      If the inside diameter is greater than the maximum inside diameter, replace the reverse clutch hub sub-assembly.

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