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Inspection [12/2015 - 08/2016]: 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 END PLAY 
    1. Using a dial indicator, measure the input shaft end play.
      GTY123543Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Standard end play

      0.012 to 1.250 mm (0.000473 to 0.0492 in.)

  3. INSPECT NO. 2 CLUTCH DISC 
    1. Check if the contact surfaces of the No. 2 clutch discs, No. 2 clutch plates and No. 2 clutch flange are worn or burnt.
      GTY111923Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:
      • If the lining of any disc is peeled off or discolored, or even if part of the groove is damaged, replace all discs.
      • Before assembling new discs, soak them in ATF for at least 15 minutes.

      If necessary, replace them.

  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 (1.0049 to 1.0057 in.)

      Maximum inside diameter

      25.546 mm (1.0057 in.)

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

  5. INSPECT NO. 1 CLUTCH DISC 
    1. Check if the contact surfaces of the No. 1 clutch discs, No. 1 clutch plates and No. 1 clutch flange are worn or burnt.
      GTY130480Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:
      • If the lining of any disc is peeled off or discolored, or even if part of the groove is damaged, replace all discs.
      • Before assembling new discs, soak them in ATF for at least 15 minutes.

      If necessary, replace them.

  6. 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 disc is peeled off or discolored, or even if part of the groove is damaged, replace all discs.
      • Before assembling new discs, soak them in ATF for at least 15 minutes.

      If necessary, replace them.

  7. INSPECT UNDERDRIVE PLANETARY GEAR ASSEMBLY 
    1. Using a feeler gauge, measure the clearance between the underdrive planetary carrier and pinion gears 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.

  8. 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.

  9. 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 disc is peeled off or discolored, or even if part of the groove is damaged, replace all discs.
      • Before assembling new discs, soak them in ATF for at least 15 minutes.

      If necessary, replace them.

  10. 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.

  11. INSPECT ONE-WAY CLUTCH ASSEMBLY 
    1. Temporarily install the one-way clutch assembly to the planetary ring gear.
      GTY694725Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      *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.

  12. INSPECT FRONT PLANETARY GEAR ASSEMBLY 
    1. Using a feeler gauge, measure the clearance between the front planetary carrier and each pinion gear at points A and B.
      GTY126595Courtesy 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.

  13. 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 disc is peeled off or discolored, or even if part of the groove is damaged, replace all discs.
      • Before assembling new discs, soak them in ATF for at least 15 minutes.

      If necessary, replace them.

  14. 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 together with the spring seat.
      GTY111584Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Standard free length

      15.79 mm (0.621 in.)

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

  15. INSPECT CLEARANCE OF NO. 2 BRAKE 
    1. Using a dial indicator, measure the piston stroke of the No. 2 brake piston while applying and releasing compressed air (200 kPa, 2.0 kgf/cm2 , 29 psi).
      GTY112063Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Standard piston stroke

      0.884 to 1.196 mm (0.0348 to 0.0471 in.)

      HINT: 

      Measure the piston stroke at 3 points where the No. 2 brake piston diameter is approximately 140 mm (5.51 in.) and calculate the average.

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

      NO. 2 BRAKE FLANGE THICKNESS

      Part No. Mark Thickness mm (in.)
      35678-08060 40 4.0 (0.157)
      35678-08070 41 4.1 (0.161)
      35678-08080 42 4.2 (0.165)
      35678-08090 43 4.3 (0.169)
      35678-08100 44 4.4 (0.173)
  16. INSPECT CLEARANCE OF NO. 1 BRAKE 
    1. Using a dial indicator, measure the piston stroke of the No. 1 brake piston while applying and releasing compressed air (200 kPa, 2.0 kgf/cm2 , 29 psi).
      GTY477985Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Standard piston stroke

      0.807 to 0.974 mm (0.0318 to 0.0383 in.)

      HINT: 

      Measure the piston stroke at 3 points where the No. 1 brake piston diameter is approximately 140 mm (5.51 in.) and calculate the average.

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

      NO. 1 BRAKE FLANGE THICKNESS

      Part No. Mark Thickness mm (in.)
      35676-07010 30 3.0 (0.118)
      35676-07020 31 3.1 (0.122)
      35676-07030 32 3.2 (0.126)
      35676-07040 33 3.3 (0.130)
      35676-07050 34 3.4 (0.134)
      35676-07060 35 3.5 (0.138)
  17. INSPECT CLEARANCE OF NO. 3 BRAKE 
    1. Using a vernier caliper and 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.
      GTY714360Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      *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 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 straightedge, measure the distance shown in the illustration (Dimension B).

      HINT: 

      Measure 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 piston stroke value using the following formula:

      Piston stroke = Dimension B - Dimension A

      Standard piston stroke

      0.599 to 0.761 mm (0.0236 to 0.0300 in.)

      1. If the piston stroke is not as specified, select an appropriate No. 3 brake flange so that the piston stroke will be within the specified range.
      NO. 3 BRAKE FLANGE THICKNESS

      Part No. Mark Thickness mm (in.)
      35679-07020 38 3.8 (0.150)
      35679-07030 39 3.9 (0.154)
      35679-07040 40 4.0 (0.157)
      35679-07050 41 4.1 (0.161)
      35679-07060 42 4.2 (0.165)
      35679-07070 43 4.3 (0.169)
  18. INSPECT CLEARANCE OF NO. 1 CLUTCH DISC 
    1. Install the direct multiple disc clutch assembly onto the transaxle rear 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 pack clearance of the No. 1 clutch.
      GTY432760Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      HINT: 

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

      Standard pack clearance

      0.606 to 0.774 mm (0.0239 to 0.0305 in.)

      1. If the pack clearance is not as specified, select an appropriate No. 1 clutch flange so that the pack clearance will be within the specified range.
      NO. 1 CLUTCH FLANGE THICKNESS

      Part No. Mark Thickness mm (in.)
      35635-08060
      35635-73010      		 30 3.0 (0.118)
      35635-08070
      35635-73020      		 31 3.1 (0.122)
      35635-08080
      35635-73030      		 32 3.2 (0.126)
      35635-08090
      35635-73040      		 33 3.3 (0.130)
      35635-08100
      35635-73050      		 34 3.4 (0.134)
      35635-08110
      35635-73060      		 35 3.5 (0.138)
      35635-08120
      35635-73070      		 36 3.6 (0.142)
  19. INSPECT CLEARANCE OF NO. 2 CLUTCH DISC 
    1. Install the direct multiple disc clutch assembly onto the transaxle rear cover sub-assembly.
      GTY205626Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using a dial indicator, measure the piston stroke of the No. 2 direct clutch piston while applying and releasing compressed air (200 kPa, 2.0 kgf/cm2 , 29 psi).

      HINT: 

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

      Standard piston stroke

      0.544 to 0.744 mm (0.0214 to 0.0293 in.)

      1. If the piston stroke is not as specified, select an appropriate No. 2 clutch flange so that the piston stroke will be within the specified range.
      NO. 2 CLUTCH FLANGE THICKNESS

      Part No. Mark Thickness mm (in.)
      35635-08060
      35635-73010      		 30 3.0 (0.118)
      35635-08070
      35635-73020      		 31 3.1 (0.122)
      35635-08080
      35635-73030      		 32 3.2 (0.126)
      35635-08090
      35635-73040      		 33 3.3 (0.130)
      35635-08100
      35635-73050      		 34 3.4 (0.134)
      35635-08110
      35635-73060      		 35 3.5 (0.138)
      35635-08120
      35635-73070      		 36 3.6 (0.142)
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