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Inspection [08/2015 - ]: Procedure

WARNING: This page is about a different variant/trim than selected.
  1. INSPECT AUTOMATIC TRANSMISSION OIL PAN SUB-ASSEMBLY 
    1. Remove the magnets and use them to collect steel particles.
    2. Carefully look at the foreign matter and particles in the pan and on the magnets to anticipate the type of wear you will find in the transmission.
      • Steel (magnetic): bearing, gear and clutch plate wear
      • Brass (non-magnetic): bush wear
  2. INSPECT NO. 2 1-WAY CLUTCH ASSEMBLY 
    GTY709575Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Hold the reverse clutch hub and turn the 1-way clutch assembly.
    2. Check that the 1-way clutch turns freely when turned clockwise and locks when turned counterclockwise.
      TEXT IN ILLUSTRATION

      Lock
      Free
  3. INSPECT REAR CLUTCH DISC 
    GTY700481Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Replace all the discs if one of the following problems is present: 1) a disc, plate or flange is worn or burnt, 2) the lining of a disc is peeled off or discolored, or 3) the grooves or printed numbers have even a little bit of damage.
      NOTE:

      When assembling new discs, soak them in ATF for at least 15 minutes before assembly.

  4. INSPECT REVERSE CLUTCH HUB SUB-ASSEMBLY 
    GTY107765Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Using a dial indicator, measure the inside diameter of the reverse clutch hub bush.

      Standard inside diameter

      35.812 to 35.837 mm (1.410 to 1.411 in.)

      Maximum inside diameter

      35.887 mm (1.413 in.)

      1. If the inside diameter is more than the maximum, replace the reverse clutch hub.
  5. INSPECT FORWARD CLUTCH HUB SUB-ASSEMBLY 
    GTY107771Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Using a dial indicator, measure the inside diameter of the forward clutch hub bush.

      Standard inside diameter

      26.037 to 26.062 mm (1.025 to 1.026 in.)

      Maximum inside diameter

      26.112 mm (1.028 in.)

      1. If the inside diameter is more than the maximum, replace the forward clutch hub.
  6. INSPECT FORWARD MULTIPLE DISC CLUTCH DISC 
    GTY700482Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Replace all the discs if one of the following problems is present: 1) a disc, plate or flange is worn or burnt, 2) the lining of a disc is peeled off or discolored, or 3) the grooves or printed numbers have even a little bit of damage.
      NOTE:

      When assembling new discs, soak them in ATF for at least 15 minutes before assembly.

  7. INSPECT FORWARD CLUTCH RETURN SPRING SUB-ASSEMBLY 
    GTY700478Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Using a vernier caliper, measure the free length of the spring together with the spring seat.

      Standard free length

      26.74 mm (1.05 in.)

  8. INSPECT DIRECT CLUTCH DISC 
    GTY733987Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Replace all the discs if one of the following problems is present: 1) a disc, plate or flange is worn or burnt, 2) the lining of a disc is peeled off or discolored, or 3) the grooves or printed numbers have even a little bit of damage.
      NOTE:

      When assembling new discs, soak them in ATF for at least 15 minutes before assembly.

  9. INSPECT REVERSE CLUTCH RETURN SPRING SUB-ASSEMBLY 
    GTY700479Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Using a vernier caliper, measure the free length of the spring together with the spring seat.

      Standard free length

      21.04 mm (0.828 in.)

  10. INSPECT DIRECT CLUTCH RETURN SPRING SUB-ASSEMBLY 
    GTY700480Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Using a vernier caliper, measure the free length of the spring together with the spring seat.

      Standard free length

      19.51 mm (0.768 in.)

  11. INSPECT NO. 3 BRAKE DISC 
    GTY110297Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Replace all the discs if one of the following problems is present: 1) a disc, plate or flange is worn or burnt, 2) the lining of a disc is peeled off or discolored, or 3) the grooves or printed numbers have even a little bit of damage.
      NOTE:

      When assembling new discs, soak them in ATF for at least 15 minutes before assembly.

  12. INSPECT NO. 3 BRAKE PISTON RETURN SPRING SUB-ASSEMBLY 
    GTY280974Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Using a vernier caliper, measure the free length of the spring together with the spring seat.

      Standard free length

      15.72 mm (0.619 in.)

  13. INSPECT FRONT PLANETARY GEAR ASSEMBLY 
    GTY102174Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Using a feeler gauge, measure the front planetary pinion gear thrust clearance.

      Standard clearance

      0.2 to 0.6 mm (0.00787 to 0.0236 in.)

      Maximum clearance

      0.65 mm (0.0256 in.)

      1. If the clearance is more than the maximum, replace the front planetary gear assembly.
    2. Using a cylinder gauge, measure the inside diameter of the front planetary gear bush.
      GTY107794Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Maximum inside diameter

      57.48 mm (2.26 in.)

      1. If the inside diameter is more than the maximum, replace the front planetary gear.
  14. INSPECT 1-WAY CLUTCH ASSEMBLY 
    GTY709576Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Install the 1-way clutch to the 1-way clutch inner race.
      TEXT IN ILLUSTRATION

      Lock
      Free
    2. Hold the 1-way clutch inner race and turn the 1-way clutch assembly. Check that the 1-way clutch turns freely when turned counterclockwise and locks when turned clockwise.
    3. Remove the 1-way clutch from the 1-way clutch inner race.
  15. INSPECT NO. 1 BRAKE DISC 
    GTY280972Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Replace all the discs if one of the following problems is present: 1) a disc, plate or flange is worn or burnt, 2) the lining of a disc is peeled off or discolored, or 3) the grooves or printed numbers have even a little bit of damage.
      NOTE:

      When assembling new discs, soak them in ATF for at least 15 minutes before assembly.

  16. INSPECT BRAKE PISTON RETURN SPRING SUB-ASSEMBLY 
    GTY280975Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Using a vernier caliper, measure the free length of the spring together with the spring seat.

      Standard free length

      17.05 mm (0.671 in.)

  17. INSPECT NO. 2 BRAKE DISC 
    GTY130113Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Replace all the discs if one of the following problems is present: 1) a disc, plate or flange is worn or burnt, 2) the lining of a disc is peeled off or discolored, or 3) the grooves or printed numbers have even a little bit of damage.
      NOTE:

      When assembling new discs, soak them in ATF for at least 15 minutes before assembly.

  18. INSPECT NO. 2 BRAKE PISTON RETURN SPRING SUB-ASSEMBLY 
    GTY280919Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Using a vernier caliper, measure the free length of the spring together with the spring seat.

      Standard free length

      17.45 mm (0.687 in.)

  19. INSPECT CENTER PLANETARY GEAR ASSEMBLY 
    GTY107790Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Using a feeler gauge, measure the center planetary pinion gear thrust clearance.

      Standard clearance

      0.12 to 0.68 mm (0.00472 to 0.0268 in.)

      Maximum clearance

      0.73 mm (0.0287 in.)

      1. If the clearance is more than the maximum, replace the center planetary gear assembly.
  20. INSPECT NO. 3 1-WAY CLUTCH ASSEMBLY 
    GTY709577Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Hold the rear planetary ring gear flange and turn the 1-way clutch. Check that the 1-way clutch turns freely when turned counterclockwise and locks when turned clockwise.
      TEXT IN ILLUSTRATION

      Lock
      Free
  21. INSPECT REAR PLANETARY RING GEAR FLANGE SUB-ASSEMBLY 
    GTY289508Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Using a dial indicator, measure the inside diameter of the rear planetary ring gear bush.

      Standard inside diameter

      32.176 to 32.201 (1.267 to 1.268 in.)

      Maximum inside diameter

      32.251 mm (1.270 in.)

      1. If the inside diameter is more than the maximum, replace the rear planetary ring gear.
  22. INSPECT INTERMEDIATE SHAFT 
    GTY691993Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Using a dial indicator, measure the intermediate shaft runout.

      Standard runout

      0.03 mm (0.00118 in.)

      Maximum runout

      0.08 mm (0.00315 in.)

      If the runout is more than the maximum, replace the intermediate shaft with a new one.

    2. Using a micrometer, measure the diameter of the intermediate shaft at the positions shown in the diagram.
      GTY729751Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Standard diameter

      A, B 

      25.962 to 25.975 mm (1.022 to 1.023 in.)

      C, D 

      32.062 to 32.075 mm (1.262 to 1.263 in.)

      Minimum diameter

      A, B 

      25.912 mm (1.02 in.)

      C, D 

      32.012 mm (1.26 in.)

      If the diameter is less than the minimum, replace the intermediate shaft with a new one.

  23. INSPECT NO. 4 BRAKE DISC 
    GTY130147Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Replace all the discs if one of the following problems is present: 1) a disc, plate or flange is worn or burnt, 2) the lining of a disc is peeled off or discolored, or 3) the grooves or printed numbers have even a little bit of damage.
      NOTE:

      When assembling new discs, soak them in ATF for at least 15 minutes before assembly.

  24. INSPECT REAR PLANETARY GEAR ASSEMBLY 
    GTY374042Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Using a feeler gauge, measure the rear planetary pinion gear thrust clearance.

      Standard clearance

      0.2 to 0.6 mm (0.00787 to 0.0236 in.)

      Maximum clearance

      0.65 mm (0.0256 in.)

      1. If the clearance is more than the maximum, replace the planetary gear assembly.
    2. Using a dial indicator, measure the inside diameter of the rear planetary gear bush.
      GTY374040Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Maximum inside diameter

      20.075 mm (0.790 in.)

      1. If the inside diameter is more than the maximum, replace the rear planetary gear assembly.
  25. INSPECT 1ST AND REVERSE BRAKE RETURN SPRING SUB-ASSEMBLY 
    GTY280918Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Using a vernier caliper, measure the free length of the spring together with the spring seat.

      Standard free length

      23.74 mm (0.935 in.)

  26. INSPECT 1ST AND REVERSE BRAKE 
    GTY107754Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Make sure the 1st and reverse brake piston moves smoothly when applying compressed air into and releasing compressed air from the transmission case.
  27. INSPECT NO. 1 BRAKE 
    GTY107809Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Make sure the No. 1 brake piston moves smoothly when applying compressed air into and releasing compressed air from the transmission case.
  28. INSPECT INDIVIDUAL PISTON OPERATION 
    1. Check the operating sound while applying compressed air into the oil holes indicated in the illustration.
      GTY701418Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      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 installation condition of the parts.

      1. No. 2 clutch (C2)
      2. No. 3 clutch (C3)
      3. No. 1 clutch (C1)
      4. No. 3 brake (B3)
      5. No. 1 brake (B1)
      6. No. 2 brake (B2)
      7. No. 4 brake (B4)
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