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Automatic Transaxle Unit: Inspection

  1. INSPECT TRANSMISSION OIL CLEANER MAGNET 
    1. Remove the magnets and use them to collect any steel chips. Examine the chips and particles in the pan and on the magnet to determine what type of wear has occurred in the transaxle.
      Fig 1: Collecting Any Steel Chips From Magnets
      G04976097Courtesy 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.

      Standard end play: 

      0.27 to 1.24 mm (0.0106 to 0.0488 in.) 

      Fig 2: Measuring Input Shaft End Play
      G05388358Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  3. INSPECT PACK CLEARANCE OF FORWARD CLUTCH 
    1. Install the forward clutch assembly onto the oil pump.
      NOTE: Be careful not to damage the oil seal ring of the oil pump.
      Fig 3: Inspecting Pack Clearance Of Forward Clutch
      G05388524Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using a dial indicator, measure the forward clutch pack clearance while applying and releasing compressed air (392 kPa, 4.0 kgf/cm2 , 57 psi).

      Pack clearance: 

      1.74 to 2.08 mm (0.0685 to 0.0819 in.) 

      If the pack clearance is less than the minimum, the parts may have been assembled incorrectly. Check and reassemble them again. If the pack clearance is still not as specified, select another flange.

      HINT:

      • As the opening is large, cover it with a piece of cloth to prevent the compressed air from being released.
      • There are 5 different thicknesses of flanges available.

        Flange Thickness 

        FLANGE THICKNESS CHART

        Mark Thickness (mm (in.)) Mark Thickness (mm (in.))
        1 3.00 (0.1181) 4 3.45 (0.1358)
        2 3.15 (0.1240) 5 3.60 (0.1417)
        3 3.30 (0.1299) - -
  4. INSPECT FORWARD MULTIPLE DISC CLUTCH DISC 
    1. Check if the contact surfaces of the discs, plates and flange are worn or burnt. If necessary, replace them.
      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.
      Fig 4: Identifying Forward Multiple Disc Clutch Disc
      G05388532Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  5. INSPECT FORWARD CLUTCH RETURN SPRING SUB-ASSEMBLY 
    1. Using a vernier caliper, measure the free length of the spring together with the spring seat.

      Standard free length: 

      28.23 mm (1.11 in.) 

      If the free length is shorter than the standard free length, replace the forward clutch return spring sub-assembly.

      Fig 5: Measuring Free Length Of Forward Clutch Return Spring
      G05388533Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  6. INSPECT FORWARD CLUTCH PISTON SUB-ASSEMBLY 
    1. Shake the piston to check that the check ball is not stuck.
    2. Check that air does not leak from the valve when applying compressed air (392 kPa, 4.0 kgf*cm2 , 57 psi).
    Fig 6: Inspecting Forward Clutch Piston Sub-Assembly
    G05582680Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  7. INSPECT MULTIPLE DISC CLUTCH HUB 
    1. Using a caliper gauge, measure the inside diameter of the multiple disc clutch hub bushing.
      Fig 7: Measuring Inside Diameter Of Multiple Disc Clutch Hub Bushing
      G05582511Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Standard inside diameter: 

      23.03 to 23.04 mm (0.906 to 0.907 in.) 

      Maximum inside diameter: 

      23.09 mm (0.909 in.) 

      NOTE:
      • If the inside diameter is greater than maximum, replace the multiple disc clutch hub with a new one.
      • Check the contact surface of the multiple disc clutch hub busing. If any scratches or discoloration is found, replace the multiple disc clutch hub with a new one.
  8. INSPECT UNDERDRIVE PLANETARY GEAR PRELOAD 
    1. Using SST, secure the underdrive planetary gear.

      SST 09387-00050 

      Fig 8: Securing Underdrive Planetary Gear Using SST 09387-00050
      G05582711Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using SST and a torque wrench, measure the underdrive planetary gear preload while rotating the torque wrench at 60 rpm.

      SST 09387-00050 

      Torque: Turning torque at 60 rpm 

      1.5 to 2.6 N*m (15 to 26 kgf*cm, 13 to 23 in.*lbf) 

      HINT:

      Use a torque wrench with a fulcrum length of 160 mm (6.30 in.)

      Fig 9: Measuring Underdrive Planetary Gear
      G05001048Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  9. INSPECT PACK CLEARANCE OF UNDERDRIVE CLUTCH 
    1. Install the underdrive clutch assembly to the transaxle.
      NOTE: Be careful not to damage the oil seal rings.
    2. Install a dial indicator as shown in the illustration.
      Fig 10: Inspecting Pack Clearance Of Underdrive Clutch
      G05388588Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Measure the underdrive clutch pack clearance while applying and releasing compressed air (392 kPa, 4.0 kgf/cm2 , 57 psi)

      Pack clearance: 

      1.51 to 1.90 mm (0.0594 to 0.0748 in.) 

      Fig 11: Measuring Underdrive Clutch Pack Clearance
      G05582744Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      If the pack clearance is less than the minimum, the parts may have been assembled incorrectly. Check and reassemble them again. If the pack clearance is still not as specified, select another flange.

      HINT:

      There are 3 different thicknesses of flanges available.

      Flange Thickness 

      FLANGE THICKNESS CHART

      Mark Thickness (mm (in.)) Mark Thickness (mm (in.))
      1 3.0 (0.118) 3 3.4 (0.134)
      2 3.2 (0.126) - -
  10. INSPECT NO. 1 UNDERDRIVE CLUTCH DISC 
    1. Check if the contact surfaces of the discs, plates and flange are worn or burnt.

      If necessary, replace them.

      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.
      Fig 12: Identifying No. 1 Underdrive Clutch Disc
      G05388597Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  11. INSPECT UNDERDRIVE CLUTCH DRUM SUB-ASSEMBLY 
    1. Using a caliper gauge, measure the inside diameter of the underdrive clutch drum bush.

      Standard drum bush inside diameter: 

      37.06 to 37.08 mm (1.459 to 1.4598 in.) 

      Maximum drum bush inside diameter: 

      37.13 mm (1.461 in.) 

      If the inside diameter is greater then the maximum, replace the underdrive clutch drum sub-assembly.

      Fig 13: Measuring Inside Diameter Of Underdrive Clutch Drum Bush
      G05388599Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  12. INSPECT UNDERDRIVE CLUTCH RETURN SPRING SUB-ASSEMBLY 
    1. Using a vernier caliper, measure the free length of the spring together with the spring seat.

      Standard free length: 

      17.14 mm (0.674 in.) 

      If the free length is shorter than the standard free length, replace the underdrive clutch return spring sub-assembly.

      Fig 14: Measuring Free Length Of Underdrive Clutch Return Spring
      G05388518Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  13. INSPECT NO. 2 UNDERDRIVE CLUTCH DISC 
    1. Check if the contact surfaces of the discs, plates and flange are worn or burnt. If necessary, replace them.
      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.
      Fig 15: Identifying No. 2 Underdrive Clutch Disc
      G05388359Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  14. INSPECT UNDERDRIVE BRAKE RETURN SPRING SUB-ASSEMBLY 
    1. Using a vernier caliper, measure the free length of the spring together with the spring seat.

      Standard free length: 

      14.04 mm (0.552 in.) 

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

      Fig 16: Measuring Free Length Of Underdrive Brake Return Spring
      G05388360Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  15. INSPECT PACK CLEARANCE OF DIRECT CLUTCH 
    1. Install the direct clutch and needle roller bearing to the transaxle rear cover.
    2. Using a dial indicator, measure the direct clutch pack clearance while applying and releasing compressed air (392 kPa, 4.0 kgf/cm2 , 57 psi).

      Pack clearance: 

      0.52 to 0.82 mm (0.0204 to 0.0322 in.) 

      Fig 17: Inspecting Pack Clearance Of Direct Clutch
      G05388546Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      If the pack clearance is less than the minimum, the parts may have been assembled incorrectly. Check and reassemble them again. If the pack clearance is still not as specified, select another flange.

      HINT:

      There are 6 different thicknesses of flanges available.

      Flange Thickness 

      FLANGE THICKNESS CHART

      Mark Thickness (mm (in.)) Mark Thickness (mm (in.))
      1 3.0 (0.118) 4 3.3 (0.130)
      2 3.1 (0.122) 5 3.4 (0.134)
      3 3.2 (0.126) 6 3.5 (0.138)
  16. INSPECT DIRECT MULTIPLE DISC CLUTCH DISC 
    1. Check if the contact surfaces of the discs, plates and flange are worn or burnt. If necessary, replace them.
      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.
      Fig 18: Identifying Direct Multiple Disc Clutch Disc
      G05388553Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  17. INSPECT DIRECT CLUTCH RETURN SPRING SUB-ASSEMBLY 
    1. Using a vernier caliper, measure the free length of the spring together with the spring seat.

      Standard free length: 

      22.58 mm (0.888 in.) 

      If the free length is shorter than the standard free length, replace the direct clutch return spring sub-assembly.

      Fig 19: Measuring Free Length Of Direct Clutch Return Spring
      G05388554Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  18. INSPECT 2ND BRAKE CLUTCH DISC 
    1. Check if the contact surfaces of the discs, plates and flange are worn or burnt.

      If necessary, replace them.

      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.
      Fig 20: Identifying 2nd Brake Clutch Disc
      G05388361Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  19. INSPECT 2ND BRAKE PISTON RETURN SPRING SUB-ASSEMBLY 
    1. Using a vernier caliper, measure the free length of the spring together with the spring seat.

      Standard free length: 

      16.61 mm (0.653 in.) 

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

      Fig 21: Measuring Free Length Of 2nd Brake Piston Return Spring
      G05388518Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  20. INSPECT 1ST AND REVERSE BRAKE CLUTCH DISC 
    1. Check if the contact surfaces of the discs, plates and flange are worn or burnt.

      If necessary, replace them.

      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.
      Fig 22: Identifying 1st And Reverse Brake Clutch Disc
      G05388362Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  21. INSPECT 1ST AND REVERSE BRAKE RETURN SPRING SUB-ASSEMBLY 
    1. Using a vernier caliper, measure the free length of the spring together with the spring seat.

      Standard free length: 

      15.51 mm (0.610 in.) 

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

      Fig 23: Measuring Free Length Of 1st And Reverse Brake Return Spring
      G05388363Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  22. INSPECT UNDERDRIVE ONE-WAY CLUTCH ASSEMBLY 
    1. Install the underdrive clutch assembly to the one-way clutch. Make sure that the underdrive one-way clutch turns freely counterclockwise and locks when turned clockwise.
      Fig 24: Inspecting Underdrive One-Way Clutch Assembly
      G05240719Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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