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Inspection [10/2017 - ]: Procedure

WARNING: This page is about a different variant/trim than selected.
  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) Brass (non-magnetic)
      Bearing, gear and plate wear 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

      Standard End Play

      0.020 to 1.242 mm (0.000788 to 0.0488 in.)

  3. INSPECT INTERMEDIATE SHAFT END PLAY 
    1. Clean the contact surfaces of the transaxle case sub-assembly and rear transaxle cover sub-assembly.
      GTY439469Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Dimension A
    2. Place a straightedge on the multiple direct clutch drum and measure the distance between the transaxle case sub-assembly and the straightedge using a vernier caliper (Dimension A).
    3. Using a vernier caliper and a straightedge, measure the distance shown in the illustration (Dimension B).
      GTY374583Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Dimension B
    4. Calculate the end play value using the following formula:

      End play = Dimension B - Dimension A - Thrust needle roller bearing thickness

      Standard End Play

      0.022 to 1.099 mm (0.000867 to 0.0432 in.)

  4. 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 (1.00492 to 1.00575 in.)

      Maximum Inside Diameter

      25.546 mm (1.00575 in.)

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

  5. INSPECT REAR PLANETARY SUN GEAR ASSEMBLY 
    1. Using a caliper gauge, measure the inside diameter of the bushing of the rear planetary sun gear assembly.
      GTY205585Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Standard Inside Diameter

      25.580 to 25.601 mm (1.00708 to 1.00791 in.)

      Maximum Inside Diameter

      25.601 mm (1.00791 in.)

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

  6. INSPECT UNDERDRIVE PLANETARY GEAR ASSEMBLY 
    1. Using a feeler gauge, measure the clearance between the underdrive planetary gear assembly and the pinion gear at 4 points.
      GTY205550Courtesy 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.

  7. INSPECT ONE-WAY CLUTCH ASSEMBLY 
    1. Temporarily install the one-way clutch assembly to the planetary ring gear.
      GTY426253Courtesy 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.

  8. 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.
      GTY173974Courtesy 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.

  9. 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.
      GTY323179Courtesy 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 discs, soak them in ATF for at least 15 minutes.

      If necessary, replace them.

  10. 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 discs, soak them in ATF for at least 15 minutes.

      If necessary, replace them.

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

      Standard Free Length

      23.26 mm (0.916 in.)

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

  12. 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 including the spring seat.
      GTY111584Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      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 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.
      GTY205581Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Standard Free Length

      9.15 mm (0.360 in.)

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

  14. INSPECT CLEARANCE OF NO. 1 BRAKE 

    HINT: 

    • Automatic transaxle assemblies manufactured at 2 different factories are available for this vehicle.
    • Refer to Introduction and check the transaxle serial number. Confirm the factory at which the automatic transaxle assembly was manufactured according to the following table.
      Serial Number Factory
      3########## for TMMWV Made
      ##A######## for AISIN AW Made
    1. Using a dial indicator, measure the clearance of the No. 1 brake while applying compressed air (200 kPa, 2.0 kgf/cm2 , 29 psi).
      GTY130482Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Standard Clearance

      0.601 to 0.819 mm (0.0237 to 0.0322 in.)

      HINT: 

      • Measure the clearance at 3 points where the No. 1 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.

      • There are 6 No. 1 brake flanges of different thicknesses (for TMMWV Made).
      • There are 7 No. 1 brake flanges of different thicknesses (for AISIN AW Made).

      No. 1 Brake Flange Thickness

      FOR TMMWV MADE:

      Thickness [mm (in.)] Mark
      3.0 (0.118) 30
      3.1 (0.122) 31
      3.2 (0.126) 32
      3.3 (0.130) 33
      3.4 (0.134) 34
      3.5 (0.138) 35
      FOR AISIN AW MADE:

      Thickness [mm (in.)] Mark
      3.0 (0.118) 30
      3.1 (0.122) 31
      3.2 (0.126) 32
      3.3 (0.130) 33
      3.4 (0.134) 34
      3.5 (0.138) 35
      3.6 (0.142) 36
  15. INSPECT CLEARANCE OF NO. 2 BRAKE 

    HINT: 

    • Automatic transaxle assemblies manufactured at 2 different factories are available for this vehicle.
    • Refer to Introduction and check the transaxle serial number. Confirm the factory at which the automatic transaxle assembly was manufactured according to the following table.
      Serial Number Factory
      3########## for TMMWV Made
      ##A######## for AISIN AW Made
    1. Using a dial indicator, measure the clearance of the No. 2 brake while applying compressed air (200 kPa, 2.0 kgf/cm2 , 29 psi).
      GTY112063Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Standard Clearance

      0.707 to 0.974 mm (0.0278 to 0.0383 in.)

      HINT: 

      • Measure the clearance at 3 points where the No. 2 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.

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

      No. 2 Brake Flange Thickness

      FOR TMMWV MADE:

      Thickness [mm (in.)] Mark
      4.0 (0.157) 40
      4.1 (0.161) 41
      4.2 (0.165) 42
      4.3 (0.169) 43
      4.4 (0.173) 44
      FOR AISIN AW MADE:

      Thickness [mm (in.)] Mark
      4.0 (0.157) 40A
      4.1 (0.161) 41A
      4.2 (0.165) 42A
      4.3 (0.169) 43A
      4.4 (0.173) 44A
  16. INSPECT CLEARANCE OF NO. 3 BRAKE 

    HINT: 

    • Automatic transaxle assemblies manufactured at 2 different factories are available for this vehicle.
    • Refer to Introduction and check the transaxle serial number. Confirm the factory at which the automatic transaxle assembly was manufactured according to the following table.
      Serial Number Factory
      3########## for TMMWV Made
      ##A######## for AISIN AW Made
    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 No. 3 brake flange.
      GTY476335Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Front Oil Pump Assembly *2 No. 3 Brake Piston
      *3 No. 3 Brake Flange - -
      *a Dimension (A) *b Dimension (B)
      *c Contact Surface of Front Oil Pump Assembly - -

      HINT: 

      Measure the distance (Dimension(A)) at 3 points where the No. 3 brake 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 distance (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 using the following formula:

      Clearance = Dimension (B) - Dimension (A)

      Standard Clearance

      0.599 to 0.799 mm (0.0236 to 0.0315 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.

    4. Adjust clearance of No. 3 brake piston:
      1. Using a screwdriver with its tip wrapped with protective tape, remove the snap ring from the front oil pump assembly.
        GTY479082Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        *a Protective Tape
      2. Remove the No. 3 brake flange from the front oil pump assembly.
        GTY476333Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        *1 No. 3 Brake Flange
      3. 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 No. 3 brake disc.
        GTY475464Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        *1 Front Oil Pump Assembly *2 No. 3 Brake Piston
        *3 No. 3 Brake Disc - -
        *a Dimension (A) *b Dimension (B)
        *c Contact Surface of Front Oil Pump Assembly - -

        HINT: 

        Measure the distance (Dimension(A)) at 3 points where the No. 3 brake disc diameter is approximately 166 mm (6.54 in.) and calculate the average.

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

        HINT: 

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

      5. Calculate the thickness of the replacement No. 3 brake flange using the following formula:

        Thickness of Replacement No. 3 Brake Flange

        Dimension (B) - Dimension (A) - (0.599 to 0.799 mm (0.0236 to 0.0315 in.))

        HINT: 

        • There are 6 No. 3 brake flanges of different thicknesses (for TMMWV Made).
        • There are 7 No. 3 brake flanges of different thicknesses (for AISIN AW Made).

        No. 3 Brake Flange Thickness

        FOR TMMWV MADE:

        Thickness [mm (in.)] Mark
        3.8 (0.150) 38
        3.9 (0.154) 39
        4.0 (0.157) 40
        4.1 (0.161) 41
        4.2 (0.165) 42
        4.3 (0.169) 43
        FOR AISIN AW MADE:

        Thickness [mm (in.)] Mark
        3.8 (0.150) 38
        3.9 (0.154) 39
        4.0 (0.157) 40
        4.1 (0.161) 41
        4.2 (0.165) 42
        4.3 (0.169) 43
        4.4 (0.173) 44
      6. Install the No. 3 brake flange to the front oil pump assembly.
        GTY476333Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        *1 No. 3 Brake Flange
      7. Using a screwdriver with its tip wrapped with protective tape, install the snap ring to the front oil pump assembly.
        GTY478364Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        NOTE:
        • Confirm that the snap ring is correctly located in the groove of the front oil pump assembly.
        • Make sure that the snap ring ends are positioned as shown in the illustration (A).
  17. 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.
      GTY442209Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Feeler Gauge

      HINT: 

      Measure the clearance at 3 points where the flange diameter is approximately 152 mm (5.98 in.) and calculate the average.

      Standard Pack Clearance

      0.601 to 0.819 mm (0.0237 to 0.0322 in.)

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

  18. 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. 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).

      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.

      Standard Pack Clearance

      0.394 to 0.605 mm (0.0155 to 0.0238 in.)

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

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