Automatic Transmission Unit: Inspection

INSPECT AUTOMATIC TRANSMISSION OIL PAN SUB-ASSEMBLY
1. Remove the magnets, and use them to collect steel particles.
2. Carefully lock at the foreign matter and particles in the pan and on the magnets to anticipate the type of wear you will find in the transmission.
  - Steel (magnetic). bearing, gear and clutch plate wear
  - Brass (non-magnetic): bushing wear
    
    Fig 1: Inspecting Particles In Pan
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT NO. 2 ONE-WAY CLUTCH ASSEMBLY
1. Hold the Reverse clutch hub and turn the No. 2 one-way clutch assembly.
2. The No. 2 one-way clutch assembly turns freely clockwise and locks when turned counterclockwise.
  
  Fig 2: Inspecting No. 2 One-Way Clutch Assembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT NO. 3 BRAKE DISC
1. Replace all discs if one of the following problems is present: 1) a disc, plate or flange is worn or burnt, 2) the lining of a disc is peeled off or discolored, or 3) grooves or printed numbers have even a little bit of damage.
  NOTE: Before assembling new discs, soak them in ATF for at least 15 minutes.
  
  Fig 3: Inspecting No. 3 Brake Disc
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT NO. 3 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: 15.72 mm (0.619 in.)
  
  Fig 4: Inspecting No. 3 Brake Piston Return Spring Sub-Assembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT FRONT PLANETARY GEAR ASSEMBLY
1. Using a feeler gauge, measure the front planetary pinion gear thrust clearance.
  Standard clearance: 0.2 to 0.60 mm (0.008 to 0.024 in.)
  
  Maximum clearance: 0.65 mm (0.026 in.)
  
  If the clearance is greater than the maximum, replace the front planetary gear assembly.
  
  Fig 5: Inspecting Front Planetary Gear Assembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using a cylinder gauge, measure the inside diameter of the front planetary gear bushing.
  Maximum inside diameter: 57.48 mm (2.263 in.)
  
  If the inside diameter is greater than the maximum, replace the front planetary gear.
  
  Fig 6: Measuring Inside Diameter Of Front Planetary Gear Bushing
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT ONE-WAY CLUTCH ASSEMBLY
1. Install the one-way clutch assembly to the one-way clutch inner race.
2. Hold the one-way clutch inner race and turn the one-way clutch assembly.
3. Check that the one-way clutch assembly turns freely counterclockwise and locks when turned clockwise.
4. Remove the one-way clutch assembly from the one-way clutch inner race.
  
  Fig 7: Inspecting One-Way Clutch Assembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT NO. 1 BRAKE DISC
1. Replace all discs if one of the following problems is present: 1) a disc, plate or flange is worn or burnt, 2) the lining of a disc is peeled off or discolored, or 3) grooves or printed numbers have even a little bit of damage.
  NOTE: Before assembling new discs, soak them in ATF for at least 15 minutes.
  
  Fig 8: Inspecting No. 1 Brake Disc
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT 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: 17.05 mm (0.671 in.)
  
  Fig 9: Inspecting Brake Piston Return Spring Sub-Assembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT NO. 2 BRAKE DISC
1. Replace all discs if one of the following problems is present: 1) a disc, plate or flange is worn or burnt, 2) the lining of a disc is peeled off or discolored, or 3) grooves or printed numbers have even a little bit of damage
  NOTE: Before assembling new discs, soak them in ATF for at least 15 minutes.
  
  Fig 10: Inspecting No. 2 Brake Disc
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT NO. 2 BRAKE PISTON RETURN SPRING SUB-ASSEMBLY
1. Using a vernier calipers, measure the free length of the spring together with the spring seat.
  Standard free length: 17.45 mm (0.687 in.)
  
  Fig 11: Inspecting No. 2 Brake Piston Return Spring Sub-Assembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT CENTER PLANETARY GEAR ASSEMBLY
1. Using a feeler gauge, measure the center planetary gear pinion thrust clearance.
  Standard clearance: 0.12 to 0.68 mm (0.005 to 0.027 in.)
  
  Maximum clearance: 0.73 mm (0.029 in.)
  
  If the clearance is greater than the maximum, replace the center planetary gear assembly.
  
  Fig 12: Inspecting Center Planetary Gear Assembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT NO. 3 ONE-WAY CLUTCH ASSEMBLY
1. Hold the rear planetary ring gear flange sub-assembly turn the one-way clutch assembly.
2. Check that the one-way clutch assembly turns freely counterclockwise and locks when turned clockwise.
  
  Fig 13: Inspecting No. 3 One-Way Clutch Assembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT REAR PLANETARY RING GEAR FLANGE SUB-ASSEMBLY
1. Using a dial indicator, measure the inside diameter of the rear planetary ring gear bushing.
  Maximum inside diameter: 32.175 mm (1.267 in.)
  
  If the inside diameter is greater than the maximum, replace the rear planetary ring gear.
  
  Fig 14: Measuring Diameter Of Rear Planetary Ring Gear Bushing
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT INTERMEDIATE SHAFT
1. Using a dial indicator, check the intermediate shaft runout.
  Maximum runout: 0.08 mm (0.003 in.)
  
  NOTE: If the bend exceeds the specification, replace the intermediate shaft with anew one.
  
  Fig 15: Checking Intermediate Shaft Runout
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using a micrometer, check the outer diameter of the intermediate shaft positions shown in the diagram.
  Standard diameter:
  
  A: 25.962 to 25.975 mm (1.022 to 1.023 in.)
  
  B: 25.962 to 25.975 mm (1.022 to 1.023 in.)
  
  C: 32.062 to 32.075 mm (1.262 to 1.263 in.)
  
  D: 32.062 to 32.075 mm (1.262 to 1.263 in.)
  
  Minimum diameter:
  
  A: 25.912 mm (1.020 in.)
  
  B: 25.912 mm (1.020 in.)
  
  C: 32.012 mm (1.260 in.)
  
  D: 32.012 mm (1.260 in.)
  
  NOTE: If the outer diameter is outside the standard, replace the intermediate shaft with the new one.
  
  Fig 16: Checking Outer Diameter Of Intermediate Shaft Positions
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT NO. 4 BRAKE DISC
1. Replace all discs if one of the following problems is present. 1) a disc, plate or flange is worn or burnt, 2) the lining of a disc is peeled off or discolored, or 3) grooves or printed numbers have even a little bit of damage.
  NOTE: Before assembling new discs, soak them in ATF for at least 15 minutes.
  
  Fig 17: Inspecting No. 4 Brake Disc
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT REAR PLANETARY GEAR ASSEMBLY
1. Using a feeler gauge, measure the rear planetary gear pinion thrust clearance.
  Standard clearance: 0.2 to 0.6 mm (0.008 to 0.024 in.)
  
  Maximum clearance: 0.65 mm (0.026 in.)
  
  If the clearance is greater than the maximum, replace the planetary gear assembly.
  
  Fig 18: Inspecting Rear Planetary Gear Assembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using a dial indicator, measure the inside diameter of the rear planetary gear bushing
  Maximum inside diameter: 20.075 mm (0.790 in.)
  
  If the inside diameter is greater than the maximum, replace the rear planetary gear assembly
  
  Fig 19: Measuring Inside Diameter Of Rear Planetary Gear Bushing
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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: 23.74 mm (0.935 in.)
  
  Fig 20: Measuring Free Length Of Spring With Spring Seat
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT PACK CLEARANCE OF FIRST AND REVERSE BRAKE
1. Make sure the 1st and reverse brake pistons move smoothly when applying and releasing the compressed air into the transmission case.
  
  Fig 21: Inspecting Pack Clearance Of First And Reverse Brake
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT NO. 1 PISTON STROKE OF BRAKE PISTON
1. Make sure the No. 1 brake piston moves smoothly when applying and releasing the compressed air into the transmission case.
  
  Fig 22: Applying Compressed Air Into Transmission Case
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using a feeler gauge, measure the B3 bearing pack clearance between the snap ring and flange.
  Piston stroke: 0.42 to 0.72 mm (0.0165 to 0.0283 in.)
  
  If the piston stroke is outside the specification, parts may have been assembled incorrectly.
  
  Perform the reassembly again.
  
  If the piston stroke is still outside the specification, select another flange.
  
  HINT:
  
  There are 4 different thicknesses for the flange
  
  Fig 23: Measuring B3 Bearing Pack Clearance Between Snap Ring And Flange
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT INDIVIDUAL PISTON OPERATION INSPECTION
1. Check the operating sound while applying compressed air into the oil holes indicated in the illustration.
  HINT:
  
  When inspecting the overdrive direct clutch, check with the C3 accumulator piston holes indicated in the illustration.
  
  If there is no sound, disassembly and check the installation condition of the parts.
  1. No. 2 clutch (C2)
  2. No. 3 clutch (C3)
  3. No. 1 clutch (C1)
  4. No. 3 brake (B1)
  5. No. 1 brake (B1)
  6. No. 2 brake (B2)
  7. No. 4 brake (B4)
    
    Fig 24: Identifying Oil Holes
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002