Automatic Transaxle - A760H: Inspection: Notes

INSPECT UNDERDRIVE 1 WAY CLUTCH ASSEMBLY
1. Hold the coast clutch hub and turn the 1 way clutch assembly.
2. Check that the 1 way clutch assembly turns freely clockwise and locks counterclockwise.
  If there is a problem with the 1 way clutch, replace it.
Fig 1: Turning Free And Lock Position Of 1 Way Clutch Assembly
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT DIRECT CLUTCH RETURN SPRING SUB-ASSEMBLY
1. Using vernier calipers, measure the free length of the spring together with the spring seat.
  Standard free length:
  
  19.51 mm (0.768 in.)
  
  If the free length is shorter than the standard free length, replace the clutch return spring sub-assembly.
Fig 2: Checking Free Length Of Spring
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT REVERSE CLUTCH RETURN SPRING SUB-ASSEMBLY
1. Using vernier calipers, measure the free length of the spring together with the spring seat.
  Standard free length:
  
  21.04 mm (0.828 in.)
  
  If the free length is shorter than the standard free length, replace the clutch return spring sub-assembly.
Fig 3: Checking Free Length Of Spring
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT DIRECT CLUTCH DISC
1. Check whether the sliding surfaces of the 4 discs, the 5 plates, and the flange are worn or burnt. If necessary, replace them.
  NOTE:
  - If the linings of the discs are peeled off or discolored, or even a part of the printed numbers is damaged, replace all discs.
  - Before assembling new discs, soak them in ATF for at least 15 minutes.
Fig 4: Inspecting Direct Clutch Disc
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

INSPECT PACK CLEARANCE OF DIRECT CLUTCH

Inspect the pack clearance of the direct clutch.

Using a dial indicator, measure the moving distance (distance A) of the clutch flange at the both ends across a diameter while blowing air to the oil hole as shown in the illustration, and calculate the average.
HINT:

Flange moving distance A = 0.26 to 1.14 mm Pack clearance = Flange moving distance A - 0.05 mm

Pack Clearance:

0.4 to 0.7 mm (0.0157 to 0.0276 in.)

NOTE: Install a selective flange (t = 3.4 mm) when measuring the moving distance, (shaded area in the illustration.)

If the pack clearance is outside the standard, select and install a clutch flange that brings the pack clearance within the standard.

HINT:

There are 9 types of flanges that can be used to adjust the pack clearance. Select the one with the most appropriate thickness.

Flange thickness

THICKNESS SPECIFIED CONDITION

No.	Thickness
0	3.0 mm (0.118 in.)
1	3.1 mm (0.122 in.)
2	3.2 mm (0.126 in.)
3	3.3 mm (0.130 in.)
4	3.4 mm (0.134 in.)
5	3.5 mm (0.138 in.)
6	3.6 mm (0.142 in.)
7	3.7 mm (0.146 in.)
8	3.8 mm (0.150 in.)

Fig 5: Measuring Moving Distance Of Clutch Flange

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

INSPECT PACK CLEARANCE OF REVERSE CLUTCH

Inspect the pack clearance of the reverse clutch hub sub-assembly.

Using a dial indicator, measure the reverse clutch piston stroke (distance A) and the moving distance (distance B) of the reverse clutch flange at the both ends across a diameter while blowing air (392 kPa, 4 kgf/cm² , 57 psi) from the oil hole as shown in the illustration, and calculate the average.

Fig 6: Measuring Reverse Clutch Piston Stroke And Moving Distance Of Reverse Flange
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

HINT:

Piston stroke A = 1.05 to 2.15 mm

Flange moving distance B = 0.72 to 1.08 mm

Pack clearance = Piston stroke A - Flange moving distance B - 0.06

Pack Clearance:

0.5 to 0.8 mm (0.020 to 0.031 in.)

NOTE: Install a selective flange (t = 3.3 mm) when measuring the moving distance. (Shaded area in the illustration)

If the pack clearance is outside the standard, select and install a clutch flange that brings the pack clearance within the standard.

HINT:

There are 11 types of flanges that can be used to adjust the pack clearance. Select the one with the most appropriate thickness.

Flange thickness

THICKNESS SPECIFIED CONDITION

No.	Thickness
0	2.8 mm (0.110 in.)
1	2.9 mm (0.114 in.)

THICKNESS SPECIFIED CONDITION

No.	Thickness
2	3.0 mm (0.118 in.)
3	3.1 mm (0.122 in.)
4	3.2 mm (0.126 in.)
5	3.3 mm (0.130 in.)
6	3.4 mm (0.134 in.)
7	3.5 mm (0.138 in.)
8	3.6 mm (0.142 in.)
9	3.7 mm (0.146 in.)
A	3.8 mm (0.150 in.)

INSPECT FORWARD CLUTCH RETURN SPRING SUB-ASSEMBLY
1. Using vernier calipers, measure the free length of the spring together with the spring seat.
  Standard free length:
  
  24.64 mm (0.9701 in.)
  
  If the free length is shorter than the standard free length, replace the clutch return spring sub-assembly.
Fig 7: Checking Free Length Of Spring
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT COAST CLUTCH DISC
1. Check whether the sliding surfaces of the 3 discs, the 3 plates and the flange are worn or burnt. If necessary, replace them.
  NOTE:
  - If the linings of the discs are peeled off or discolored, or even a part of the printed numbers is damaged, replace all discs.
  - Before assembling new discs, soak them in ATF for at least 15 minutes.
Fig 8: Inspecting Coast Clutch Disc
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

INSPECT PACK CLEARANCE OF COAST CLUTCH

Inspect the pack clearance of the coast clutch hub sub-assembly.

Using a dial indicator, measure the moving distance (distance A) of the clutch flange at the both ends across a diameter while blowing air from the oil hole as shown in the illustration, and calculate the average.
HINT:

Flange moving distance A = 0.38 to 1.48 mm (0.01496 to 0.0583 in.)

Pack clearance = Flange moving distance A - 0.02 mm (0.0008 in.)

Pack Clearance:

0.3 to 0.6 mm (0.012 to 0.024 in.)

NOTE: Install a selective flange (t = 3.0 mm) when measuring the moving distance, (shaded area in the illustration.)

Fig 9: Measuring Moving Distance Of Clutch Flange At Both Ends
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

If the pack clearance is outside the standard, select and install a clutch flange that brings the pack clearance within the standard.

HINT:

There are 10 types of flanges that can be used to adjust the pack clearance. Select the one with the most appropriate thickness.

Flange thickness

THICKNESS SPECIFIED CONDITION

No.	Thickness
0	3.0 mm (0.118 in.)
1	3.1 mm (0.122 in.)
2	3.2 mm (0.126 in.)
3	3.3 mm (0.130 in.)
4	3.4 mm (0.134 in.)
5	3.5 mm (0.138 in.)
6	3.6 mm (0.142 in.)
7	3.7 mm (0.146 in.)
8	3.8 mm (0.150 in.)
9	3.9 mm (0.154 in.)

INSPECT FORWARD CLUTCH HUB CLUTCH DISC
1. Check whether the sliding surfaces of the 4 discs, the 5 plates, and the flange are worn or burnt. If necessary, replace them.
  NOTE:
  - If the linings of the discs are peeled off or discolored, or even a part of the printed numbers is damaged, replace all discs.
  - Before assembling new discs, soak them in ATF for at least 15 minutes.

INSPECT PACK CLEARANCE OF FORWARD CLUTCH

Inspect the pack clearance of the forward clutch.

Using a dial indicator, measure the moving distance (distance A) of the clutch flange at the both ends across a diameter while blowing air from the oil hole as shown in the illustration, and calculate the average.
HINT:

Flange moving distance A = 0.36 to 1.50 mm Pack clearance = Flange moving distance A -0.11 mm

Pack Clearance:

0.56 to 0.86 mm (0.0220 to 0.0339 in.)

NOTE: Install a selective flange (t = 3.4 mm) when measuring the moving distance, (shaded area in the illustration.)

Fig 10: Inspecting Pack Clearance Of Forward Clutch
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Fig 11: Measuring Moving Distance Of Clutch Flange At Both Ends
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

If the pack clearance is outside the standard, select and install a clutch flange that brings the pack clearance within the standard.

HINT:

There are 11 types of flanges that can be used to adjust the pack clearance. Select the one with the most appropriate thickness.

Flange thickness

THICKNESS SPECIFIED CONDITION

No.	Thickness
0	3.0 mm (0.118 in.)
1	3.1 mm (0.122 in.)
2	3.2 mm (0.126 in.)
3	3.3 mm (0.130 in.)
4	3.4 mm (0.134 in.)
5	3.5 mm (0.138 in.)
6	3.6 mm (0.142 in.)
7	3.7 mm (0.146 in.)
8	3.8 mm (0.150 in.)
9	3.9 mm (0.154 in.)
A	4.0 mm (0.158 in.)

INSPECT FORWARD CLUTCH HUB SUB-ASSEMBLY
1. Using a dial indicator, measure the inside diameter of the forward clutch hub bushing.
  Standard inside diameter:
  
  26.037 to 26.062 mm (1.0251 to 1.0261 in.)
  
  If the inside diameter is greater than the standard inside diameter, replace the forward clutch hub.
Fig 12: Checking Inside Diameter Of Clutch Hub Bushing
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT REAR CLUTCH DISC
1. Check whether the sliding surfaces of the 5 discs, the 4 plates, and the flange are worn or burnt. If necessary, replace them.
  NOTE:
  - If the linings of the discs are peeled off or discolored, or even a part of the printed numbers is damaged, replace all discs.
  - Before assembling new discs, soak them in ATF for at least 15 minutes.
Fig 13: Inspecting Rear Clutch Disc
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT REVERSE CLUTCH HUB SUB-ASSEMBLY
1. Using a dial indicator, measure the inside diameter of the reverse clutch hub bushing.
  Standard inside diameter:
  
  35.812 to 35.837 mm (1.4099 to 1.4109 in.)
  
  If the inside diameter is greater than the standard inside diameter, replace the reverse clutch hub.
Fig 14: Checking Inside Diameter Of Reverse Clutch Hub Bushing
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002