Automatic Transaxle Unit: Inspection

INSPECT MULTIPLE DISC CLUTCH HUB
1. Using a dial indicator, 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 1: Measuring Inside Diameter Of Forward Clutch Hub Bushing
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT UNDERDRIVE CLUTCH DISC NO.2
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 discolors, or if a part of the groove is worn, replace all discs.
  - Before installing new discs, immerse them in ATF for at least 15 minutes.
Fig 2: Inspecting Underdrive Clutch Disc No. 2
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT OVERDRIVE DIRECT CLUTCH DRUM SUB-ASSEMBLY
1. Using a dial indicator, 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 discolors, or if a part of the groove is worn, replace all 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 1ST AND REVERSE 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 discolors, or if a part of the groove is worn, replace all discs.
  - Before installing new discs, immerse them in ATF for at least 15 minutes.
Fig 5: Identifying 1st And Reverse Brake Clutch Disc
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT 1ST AND REVERSE BRAKE RETURN SPRING SUB-ASSEMBLY
1. Using a vernier calipers, measure the free length of the spring together with the spring seat.
  Standard free length:
  
  17.61 mm (0.6933 in.)
  
  HINT:
  
  If the result is not as specified, replace the spring.
Fig 6: Measuring Free Length Of Spring
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT UNDERDRIVE BRAKE RETURN SPRING SUB-ASSEMBLY
1. Using a vernier calipers, measure the free length of the spring together with the spring seat.
  Standard free length:
  
  13.24 mm (0.5213 in.)
  
  HINT:
  
  If the result is not as specified, replace the spring.
Fig 7: Measuring Free Length Of Spring
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

INSPECT PACK CLEARANCE OF 1ST AND REVERSE BRAKE

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

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

Pack clearance:

1.16 to 1.35 mm (0.0457 to 0.0531 in.)

HINT:

Piston stroke = Dimension A - Flange thickness

Flange thickness: mm (in.)

FLANGE THICKNESS CHART

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

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

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Install the flange.

INSPECT PACK CLEARANCE OF 2ND BRAKE

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

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

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.)

Flange thickness: mm (in.)

FLANGE THICKNESS CHART

Mark	Thickness	Mark	Thickness
1	3.0 (0.118)	5	3.4 (0.134)
2	3.1 (0.122)	6	3.5 (0.138)
3	3.2 (0.126)	7	3.6 (0.142)
4	3.3 (0.130)	8	-

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

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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).

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.

Flange thickness: mm (in.)

FLANGE THICKNESS CHART

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

Fig 10: Measuring Underdrive Brake Pack Clearance

Temporarily remove the snap ring and attach it to the flange.
Reinstall the snap ring.

INSPECT UNDERDRIVE 1-WAY CLUTCH ASSEMBLY
1. Install the underdrive clutch assembly to the 1-way clutch.
2. Rotate the underdrive 1-way clutch assembly to check the rotating direction for the lock or free operation.
  HINT:
  
  If the result is not as specified, replace the underdrive 1-way clutch.
Fig 11: Inspecting Underdrive 1-Way Clutch Assembly
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT INPUT SHAFT END PLAY
1. Using a dial indicator, measure the input shaft end play.
  End play:
  
  0.262 to 1.244 mm (0.01 to 0.049 in.)
  
  HINT:
  
  If the result is not as specified, replace the input shaft or thrust needle roller bearing.
Fig 12: Measuring Input Shaft End Play
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002