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Inspection [11/2015 - 11/2016]: Procedure

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  1. INSPECT TRANSMISSION OIL CLEANER MAGNET 
    1. Use the removed transmission oil cleaner magnets to collect any steel chips. Examine the chips and particles in the automatic transaxle oil pan sub-assembly and on the transmission oil cleaner magnets to determine what type of wear has occurred in the automatic transaxle assembly:
      GTY111851Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Result

      Steel (magnetic) 

      Bearing, gear and plate wear

      Brass (non-magnetic) 

      Bushing wear

  2. INSPECT INPUT SHAFT SUB-ASSEMBLY END PLAY 
    1. Using a dial indicator, measure the input shaft sub-assembly end play.
      GTY123543Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      End Play

      0.012 to 1.250 mm (0.000472 to 0.0492 in.)

  3. INSPECT PLANETARY SUN GEAR SUB-ASSEMBLY 
    1. Using a caliper gauge, measure the inside diameter of the bushings of the planetary sun gear sub-assembly.
      GTY111918Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Standard Inside Diameter

      25.525 to 25.546 mm (1.0049 to 1.0058 in.)

      Maximum Inside Diameter

      25.546 mm (1.0058 in.)

      If the inside diameter is greater than the maximum, replace the planetary sun gear sub-assembly.

  4. INSPECT NO. 3 BRAKE DISC 
    1. Check if the contact surfaces of the No. 3 brake discs, No. 3 brake plates and No. 3 brake flanges are worn or burnt.
      GTY111917Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:
      • If the lining of any No. 3 brake disc is peeled off or discolored, or even if part of the groove is damaged, replace all No. 3 brake discs.
      • Before assembling new No. 3 brake discs, soak them in ATF for at least 15 minutes.

      If necessary, replace them.

  5. INSPECT UNDERDRIVE PLANETARY GEAR ASSEMBLY 
    1. Using a feeler gauge, measure the clearance between the underdrive planetary gear assembly and pinion gear at 4 points.
      GTY425747Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Standard Clearance

      0.18 to 0.54 mm (0.00709 to 0.0213 in.)

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

  6. INSPECT REAR PLANETARY SUN GEAR ASSEMBLY 
    1. Using a caliper gauge, measure the inside diameter of the bushings of the rear planetary sun gear assembly.
      GTY111922Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Standard Inside Diameter

      25.580 to 25.601 mm (1.0071 to 1.0079 in.)

      Maximum Inside Diameter

      25.601 mm (1.0079 in.)

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

  7. INSPECT NO. 1 BRAKE DISC 
    1. Check if the contact surfaces of the No. 1 brake discs, No. 1 brake plates and No. 1 brake flange are worn or burnt.
      GTY111917Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:
      • If the lining of any No. 1 brake disc is peeled off or discolored, or even if part of the groove is damaged, replace all No. 1 brake discs.
      • Before assembling new No. 1 brake discs, soak them in ATF for at least 15 minutes.

      If necessary, replace them.

  8. INSPECT 2ND BRAKE PISTON RETURN SPRING SUB-ASSEMBLY 
    1. Using a vernier caliper, measure the free length of the 3 2nd brake piston return spring sub-assemblies including the spring seats.
      GTY130483Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Standard Free Length

      23.85 mm (0.939 in.)

      If the free length is shorter than the standard free length, replace the 2nd brake piston return spring sub-assembly.

  9. INSPECT ONE-WAY CLUTCH ASSEMBLY 
    1. Temporarily install the one-way clutch assembly to the planetary ring gear.
      GTY426257Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Planetary Ring Gear
      *2 One-way Clutch Assembly
      *a Free
      *b Lock
    2. Make sure that the one-way clutch assembly turns freely counterclockwise and locks when turned clockwise.

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

  10. INSPECT FRONT PLANETARY GEAR ASSEMBLY 
    1. Using a feeler gauge, measure the clearance between the front planetary gear case and each pinion gear at points (A) and (B).
      GTY439893Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Standard Clearance

      Point (A) 

      0.23 to 0.59 mm (0.00906 to 0.0232 in.)

      Point (B) 

      0.16 to 0.66 mm (0.00630 to 0.0259 in.)

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

  11. INSPECT NO. 2 BRAKE DISC 
    1. Check if the contact surfaces of the No. 2 brake discs, No. 2 brake plates and No. 2 brake flange are worn or burnt.
      GTY124121Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:
      • If the lining of any No. 2 brake disc is peeled off or discolored, or even if part of the groove is damaged, replace all No. 2 brake discs.
      • Before assembling new No. 2 brake discs, soak them in ATF for at least 15 minutes.

      If necessary, replace them.

  12. INSPECT 1ST AND REVERSE BRAKE RETURN SPRING SUB-ASSEMBLY 
    GTY111584Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Using a vernier caliper, measure the free length of the 1st and reverse brake return spring sub-assembly including the spring seat.

      Standard Free Length

      15.79 mm (0.622 in.)

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

  13. INSPECT CLEARANCE OF NO. 2 BRAKE 
    1. Apply compressed air to the oil pressure supply hole shown in the illustration, and check the operation of the No. 2 brake piston.
      GTY479110Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 No. 2 Brake Piston
      *a Clearance
    2. Set a dial indicator as shown in the illustration.
    3. Using a dial indicator, measure the clearance of the No. 2 brake while applying compressed air (200 kPa, 2.0 kgf/cm2 , 29 psi).

      Standard Clearance

      0.884 to 1.196 mm (0.0348 to 0.0471 in.)

      HINT: 

      Measure the clearance at 3 points where the brake piston diameter is approximately 140 mm (5.51 in.) and calculate the average.

      If the clearance is not as specified, select an appropriate No. 2 brake flange so that the clearance will be within the specified range.

      HINT: 

      There are 5 No. 2 brake flanges of different thicknesses.

      NO. 2 BRAKE FLANGE THICKNESS: MM (IN.)

      Mark Thickness
      40 4.0 (0.157)
      41 4.1 (0.161)
      42 4.2 (0.165)
      43 4.3 (0.169)
      44 4.4 (0.173)
  14. INSPECT CLEARANCE OF NO. 1 BRAKE 
    1. Apply compressed air to the oil pressure supply hole shown in the illustration, and check the operation of the No. 1 brake piston.
      GTY475225Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 No. 1 Brake Piston
      *a Clearance
    2. Set a dial indicator as shown in the illustration.
    3. Using a dial indicator, measure the clearance of the No. 1 brake while applying compressed air (200 kPa, 2.0 kgf/cm2 , 29 psi).

      Standard Clearance

      0.807 to 0.974 mm (0.0318 to 0.0383 in.)

      HINT: 

      Measure the clearance at 3 points where the brake piston diameter is approximately 140 mm (5.51 in.) and calculate the average.

      If the clearance is not as specified, select an appropriate No. 1 brake flange so that the clearance will be within the specified range.

      HINT: 

      There are 6 No. 1 brake flanges of different thicknesses.

      NO. 1 BRAKE FLANGE THICKNESS: MM (IN.)

      Mark Thickness
      30 3.0 (0.118)
      31 3.1 (0.122)
      32 3.2 (0.126)
      33 3.3 (0.130)
      34 3.4 (0.134)
      35 3.5 (0.138)
  15. INSPECT CLEARANCE OF NO. 3 BRAKE 
    1. Using a vernier caliper and a straightedge, measure the distance shown in the illustration (Dimension (A)) while a load of 500 N (51 kgf, 112.4 lbf) is being applied to the flange.
      GTY473478Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Front Oil Pump Assembly
      *2 No. 3 Brake Piston
      *a Dimension (A)
      *b Dimension (B)
      *c Contact surface of front oil pump assembly

      HINT: 

      Measure the dimension (A) at 3 points where the flange diameter is approximately 166 mm (6.54 in.) and calculate the average.

    2. Using a vernier caliper and a straightedge, measure the distance shown in the illustration (Dimension (B)).

      HINT: 

      Measure the dimension (B) at 3 points where the No. 3 brake piston diameter is approximately 166 mm (6.54 in.) and calculate the average.

    3. Calculate the clearance value using the following formula:

      Clearance = Dimension (B) - Dimension (A)

      Standard Clearance

      0.599 to 0.761 mm (0.0236 to 0.0300 in.)

      If the clearance is not as specified, select an appropriate No. 3 brake flange so that the clearance will be within the specified range.

      HINT: 

      There are 6 No. 3 brake flanges of different thicknesses.

      NO. 3 BRAKE FLANGE THICKNESS: MM (IN.)

      Mark Thickness
      38 3.8 (0.150)
      39 3.9 (0.154)
      40 4.0 (0.157)
      41 4.1 (0.161)
      42 4.2 (0.165)
      43 4.3 (0.169)
  16. INSPECT CLEARANCE OF NO. 1 CLUTCH DISC 
    1. Install the direct multiple disc clutch assembly to the rear transaxle cover sub-assembly.
      GTY186572Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Check that the piston moves when compressed air (200 kPa, 2.0 kgf/cm2 , 29 psi) is applied to the oil hole.
    3. Using a feeler gauge, measure the No. 1 clutch pack clearance.

      Pack Clearance

      0.606 to 0.774 mm (0.0239 to 0.0305 in.)

      HINT: 

      Measure the clearance at 3 points where the No. 1 clutch flange diameter is approximately 152 mm (5.98 in.) and calculate the average.

      If the pack clearance is not as specified, replace the direct multiple disc clutch assembly.

      GTY605128Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Feeler Gauge
  17. INSPECT CLEARANCE OF NO. 2 CLUTCH DISC 
    1. Install the direct multiple disc clutch assembly to the rear transaxle cover sub-assembly.
      GTY205626Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Check that the piston moves when compressed air (200 kPa, 2.0 kgf/cm2 , 29 psi) is applied to the oil hole.
    3. Using a dial indicator, measure the No. 2 clutch pack clearance while applying and releasing compressed air (200 kPa, 2.0 kgf/cm2 , 29 psi).

      Pack Clearance

      0.544 to 0.744 mm (0.0214 to 0.0293 in.)

      HINT: 

      Measure the clearance at 3 points where the diameter of the No. 2 direct multiple clutch piston is approximately 152 mm (5.98 in.) and calculate the average.

      If the pack clearance is not as specified, replace the direct multiple disc clutch assembly.

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