Automatic Transmission Unit: Inspection

INSPECT AUTOMATIC TRANSMISSION OIL PAN SUB-ASSEMBLY
1. Remove the magnets, and use them to collect steel particles.
2. Carefully look 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): bush wear
Fig 1: Identifying Steel Particles
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT NO. 2 1 -WAY CLUTCH ASSEMBLY
1. Hold the reverse clutch hub and turn the 1-way clutch assembly. Check that the 1-way clutch turns freely clockwise and locks when turned counterclockwise.
Fig 2: Inspecting No. 2 1 -Way Clutch Assembly
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT REAR CLUTCH 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 have even a little bit of damage.
  NOTE: Before assembling new discs, soak them in ATF for at least 2 hours.
  
  Fig 3: Identifying 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 bush.
  Standard inside diameter:
  
  41.912 to 41.937 mm (1.410 to 1.411 in.)
  
  If the inside diameter is more than the standard, replace the reverse clutch hub.
  
  Fig 4: Inspecting Reverse Clutch Hub Sub-Assembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT FORWARD CLUTCH HUB SUB-ASSEMBLY
1. Using a dial indicator, measure the inside diameter of the forward clutch hub bush.
  Standard inside diameter:
  
  30.200 to 30.225 mm (1.189 to 1.190 in.)
  
  If the inside diameter is more than the standard, replace the forward clutch hub.
  
  Fig 5: Measuring Inside Diameter Of Forward Clutch Hub Bush
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT NO. 4 1 -WAY CLUTCH ASSEMBLY
1. Hold the coast clutch hub and turn the 1-way clutch assembly. Check that the 1-way clutch turns freely clockwise and locks when turned counterclockwise.
Fig 6: Inspecting No. 4 1 -Way Clutch Assembly
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT FORWARD MULTIPLE DISC CLUTCH 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 2 hours.
  
  Fig 7: Inspecting Forward Multiple Disc Clutch Disc
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT COAST CLUTCH 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 2 hours.
  
  Fig 8: Inspecting Coast Clutch Disc
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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:
  
  29.65 mm (1.17 in.)
  
  Fig 9: Measuring Free Length Of Spring Together With Spring Seat
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT DIRECT CLUTCH 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 2 hours.
  
  Fig 10: Inspecting Direct Clutch Disc
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT REVERSE 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:
  
  21.24 mm (0.836 in.)
  
  Fig 11: Measuring Free Length Of Spring Together With Spring Seat
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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:
  
  19.46 mm (0.766 in.)
  
  Fig 12: Measuring Free Length Of Spring Together With Spring Seat
  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 2 hours.
  
  Fig 13: 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 14: Measuring Free Length Of Spring Together With Spring Seat
  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 0.6 mm (0.00787 to 0.0236 in.)
  
  If the clearance is more than the standard, replace the front planetary gear assembly.
  
  Fig 15: Measuring Front Planetary Pinion Gear Thrust Clearance
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using a cylinder gauge, measure the inside diameter of the front planetary gear bush.
  Standard inside diameter:
  
  61.005 to 61.030 mm (2.402 to 2.403 in.)
  
  If the inside diameter is more than the standard, replace the front planetary gear.
  
  Fig 16: Measuring Inside Diameter Of Front Planetary Gear Bush
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT 1-WAY CLUTCH ASSEMBLY
1. Install the 1-way clutch to the 1-way clutch inner race.
2. Hold the 1-way clutch inner race and turn the 1-way clutch. Check that the 1-way clutch turns freely counterclockwise and locks when turned clockwise.
3. Remove the 1 -way clutch from the 1 -way clutch inner race.
Fig 17: Inspecting 1-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 2 hours.
  
  Fig 18: 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 19: Measuring Free Length Of Spring Together
  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 2 hours.
  
  Fig 20: Inspecting No. 2 Brake Disc
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT NO. 2 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:
  
  22.66 mm (0.892 in.)
  
  Fig 21: Identifying 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 pinion gear thrust clearance.
  Standard clearance:
  
  0.20 to 0.60 mm (0.00787 to 0.0236 in.)
  
  If the clearance is more than the standard, replace the center planetary gear assembly.
Fig 22: Measuring Center Planetary Pinion Gear Thrust Clearance
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT NO. 3 1-WAY CLUTCH ASSEMBLY
1. Hold the rear planetary ring gear flange and turn the 1-way clutch. Check that the 1-way clutch turns freely counterclockwise and locks when turned clockwise.
Fig 23: Inspecting No. 3 1-Way Clutch Assembly
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT INTERMEDIATE SHAFT
1. Using a dial indicator, check the intermediate shaft runout.
  Standard runout:
  
  0.03 mm (0.00118 in.)
  
  If the runout is more than the standard, replace the intermediate shaft with a new one.
  
  Fig 24: Inspecting Intermediate Shaft
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using a micrometer, check the diameter of the intermediate shaft at the positions shown in the diagram.
  Standard diameter:
  
  A:
  
  19.963 to 19.976 mm (0.7859 to 0.7865 in.)
  
  B, C:
  
  30.150 to 30.163 mm (1.187 to 1.188 in.)
  
  D, E:
  
  36.404 to 36.420 mm (1.433 to 1.434 in.)
  
  If the diameter is less than the standard, replace the intermediate shaft with a new one.
Fig 25: Checking Diameter Of Intermediate Shaft
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 2 hours.
Fig 26: 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 pinion gear thrust clearance.
  Standard clearance:
  
  0.2 to 0.6 mm (0.00787 to 0.0236 in.)
  
  If the clearance is more than the standard, replace the planetary gear assembly.
  
  Fig 27: Measuring Rear Planetary Pinion Gear Thrust Clearance
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using a dial indicator, measure the inside diameter of the rear planetary gear bush.
  Standard inside diameter:
  
  20.0 to 20.025 mm (0.787 to 0.788 in.)
  
  If the inside diameter is more than the standard, replace the rear planetary gear assembly.
  
  Fig 28: Measuring Inside Diameter Of Rear Planetary Gear Bush
  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:
  
  23.54 to 23.94 mm (0.927 to 0.943 in.)
  
  Fig 29: Measuring Free Length Of Spring Together With Spring Seat
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT INDIVIDUAL PISTON OPERATION
1. Check the operating sound while applying compressed air into the oil holes indicated in the illustration.
  HINT:
  
  When inspecting the direct clutch, check with the accumulator piston holes indicated in the illustration. If there is no sound, disassemble and check the installation condition of the parts.
  1. No. 2 clutch (C2)
  2. No. 3 clutch (C3)
  3. No. 4 clutch (C4)
  4. No. 1 clutch (C1)
  5. No. 3 brake (B3)
  6. No. 1 brake (B1)
  7. No. 2 brake (B2)
  8. No. 4 brake (B4)
  Fig 30: Inspecting Individual Piston Operation
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002