Automatic Transaxle Unit: Inspection

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INSPECT MULTIPLE DISC CLUTCH HUB
1. Using a caliper gauge, measure the inside diameter of the forward clutch hub bushing.
  Standard inside diameter:
  
  23.03 to 23.05 mm (0.9067 to 0.9075 in.)
  
  Maximum inside diameter:
  
  23.09 mm (0.9091 in.)
  
  NOTE: Check the contact surface of the bushing in the direct clutch shaft. If any scratch or discoloration is found, replace the direct clutch sub-assembly with a new one.
  
  If the inside diameter is greater than the maximum, replace the forward clutch hub with a new one.
  
  Fig 1: Measuring Inside Diameter Of Forward Clutch Hub Bushing
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT NO. 2 UNDERDRIVE CLUTCH DISC
1. Check if the sliding surfaces of the disc, plate and flange are worn or burnt. If necessary, replace them.
  NOTE:
  - If the lining of the disc comes off or is discolored, or if a part of the groove is worn, replace all the discs.
  - Before installing new discs, immerse them in ATF for at least 15 minutes.
    
    Fig 2: Identifying No. 2 Underdrive Clutch Disc
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT OVERDRIVE DIRECT CLUTCH DRUM SUBASSEMBLY
1. Using a caliper gauge, measure the inside diameter of the forward clutch hub bushing.
  Standard inside diameter:
  
  23.025 to 23.046 mm (0.9065 to 0.9073 in.)
  
  Maximum inside diameter:
  
  23.09 mm (0.9091 in.)
  
  NOTE: Check the contact surface of the bushing in the direct clutch shaft. If any scratch or discoloration is found, replace the direct clutch sub-assembly with a new one.
  
  If the inside diameter is greater than the maximum, replace the forward clutch hub with a new one.
  
  Fig 3: Measuring Inside Diameter Of Forward Clutch Hub Bushing
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT 2ND BRAKE CLUTCH DISC
1. Check if the sliding surface of the disc, plate and flange are worn or burnt.
  If necessary, replace them.
  NOTE:
  - If the lining of the disc comes off or is discolored, or if a part of the groove is worn, replace all the discs.
  - Before installing new discs, immerse them in ATF for at least 15 minutes.
    
    Fig 4: Identifying 2nd Brake Clutch Disc
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT 1 ST AND REVERSE BRAKE CLUTCH DISC

Fig 5: Identifying 1st And Reverse Brake Clutch Disc
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
1. Check if the sliding surface of the disc, plate and flange are worn or burnt.
  If necessary, replace them.
  NOTE:
  - If the lining of the disc comes off or is discolored, or if a part of the groove is worn, replace all the discs.
  - Before installing new discs, immerse them in ATF for at least 15 minutes.
INSPECT 1ST AND REVERSE BRAKE RETURN SPRING SUB-ASSEMBLY
1. Using a vernier caliper, measure the free length of the spring together with the spring seat.
  Standard free length:
  
  17.61 mm (0.6933 in.)
  
  If the result is not as specified, replace the spring.
  
  Fig 6: Identifying Free Length Of Spring
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT UNDERDRIVE BRAKE RETURN SPRING SUB-ASSEMBLY
1. Using a vernier caliper, measure the free length of the spring together with the spring seat.
  Standard free length:
  
  13.24 mm (0.5213 in.)
  
  If the result is not as specified, replace the spring.
  
  Fig 7: Identifying Free Length Of Spring
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

INSPECT PACK CLEARANCE OF 1ST AND REVERSE BRAKE

Using a vernier caliper, measure the distance between the disc surface and the contact surface of the 2nd brake cylinder and transaxle case (Dimension A).

Fig 8: Identifying Distance Between Disc Surface And Contact Surface Of 2nd Brake Cylinder

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Select an appropriate flange so that the pack clearance will meet the specified value.

Standard pack clearance:

1.16 to 1.35 mm (0.0457 to 0.0531 in.)

HINT:

Piston stroke = Dimension A - Flange thickness

Standard flange thickness

THICKNESS SPECIFICATION CHART

Mark	Thickness	Mark	Thickness
1	1.8 mm (0.071 in.)	5	2.2 mm (0.087 in.)
2	1.9 mm (0.075 in.)	6	2.3 mm (0.091 in.)
3	2.0 mm (0.079 in.)	7	2.4 mm (0.094 in.)
4	2.1 mm (0.083 in.)	8	2.5 mm (0.098 in.)

INSPECT PACK CLEARANCE OF 2ND BRAKE

Using a vernier caliper, measure the distance between the disc surface and snap ring surface (Dimension B).

Fig 9: Identifying Distance Between Disc Surface And Snap Ring Surface

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Select an appropriate flange so that the pack clearance will meet the specified value.

Standard pack clearance:

0.62 to 0.91 mm (0.0244 to 0.0358 in.)

HINT:

Piston stroke = Dimension B - Flange thickness - Snap ring thickness 1.6 mm (0.063 in.)

Standard flange thickness

THICKNESS SPECIFICATION CHART

Mark	Thickness	Mark	Thickness
1	3.0 mm (0.118 in.)	5	3.4 mm (0.134 in.)
2	3.1 mm (0.122 in.)	6	3.5 mm (0.138 in.)
3	3.2 mm (0.126 in.)	7	3.6 mm (0.142 in.)
4	3.3 mm (0.130 in.)	-	-

INSPECT PACK CLEARANCE OF UNDERDRIVE BRAKE

Using a dial indicator, measure the underdrive brake pack clearance while applying and releasing compressed air (392 kPa, 4.0 kgf/cm² , 57 psi).

Fig 10: Identifying Underdrive Brake Pack Clearance

Standard pack clearance:

1.81 to 2.20 mm (0.0713 to 0.0866 in.)

HINT:

Select an appropriate flange from the table below so that it will meet the specified value.

Standard flange thickness

THICKNESS SPECIFICATION CHART

Mark	Thickness	Mark	Thickness
1	3.0 mm (0.118 in.)	4	3.1 mm (0.122 in.)
2	3.2 mm (0.126 in.)	5	3.3 mm (0.130 in.)
3	3.4 mm (0.134 in.)	-	-

INSPECT UNDERDRIVE 1-WAY CLUTCH ASSEMBLY
1. Install the underdrive clutch assembly to the 1-way clutch.
2. Check that the underdrive 1-way clutch locks when turned clockwise and rotates freely when turned counterclockwise as shown in the illustration.
  If the result is not as specified, replace the underdrive 1-way clutch.
INSPECT INPUT SHAFT END PLAY
1. Using a dial indicator, measure the input shaft end play.
  Standard end play:
  
  0.262 to 1.244 mm (0.0103 to 0.0490 in.)
  
  If the result is not as specified, replace the input shaft or thrust needle roller bearing.
  
  Fig 12: Identifying Input Shaft End Play
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002