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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.

      Result: 

      Steel (magnetic): 

      bearing, gear, and plate wear 

      Brass (non-magnetic): 

      bushing wear 

      Fig 1: Inspecting Transmission Oil Cleaner Magnet
      G04976097Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  2. INSPECT FRONT CLUTCH DISC 
    1. Check whether the contact surfaces of the discs, plates and flanges 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 the discs.
    • Before assembling new discs, soak them in ATF for at least 15 minutes.
      Fig 2: Identifying Front Clutch Disc
      G04831343Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  3. 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: 21.69 mm (0.853 in.) 

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

      Fig 3: Measuring Free Length Of Spring
      G04831480Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  4. INSPECT OVERDRIVE 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: 17.88 mm (0.703 in.) 

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

      Fig 4: Measuring Free Length Of Spring
      G04831346Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  5. INSPECT REVERSE CLUTCH DISC 
    1. Check whether the contact surfaces of the discs, plates and flanges 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 the discs.
    • Before assembling new discs, soak them in ATF for at least 15 minutes.
      Fig 5: Identifying Reverse Clutch Disc
      G04831507Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  6. INSPECT DIRECT CLUTCH DISC 
    1. Check whether the contact surfaces of the discs, plates and flanges 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 the discs.
    • Before assembling new discs, soak them in ATF for at least 15 minutes.
      Fig 6: Identifying Direct Clutch Disc
      G04831508Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  7. 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: 31.7 mm (1.248 in.) 

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

      Fig 7: Measuring Free Length Of Spring
      G04831509Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  8. INSPECT DIRECT CLUTCH PISTON SUB-ASSEMBLY 
    1. Shake the direct clutch pin and confirm that the check ball is not stuck.
    2. Apply low pressure compressed air to the check ball and confirm that there is no air leakage.
      Fig 8: Applying Low Pressure Compressed Air To Check Ball
      G04831510Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  9. INSPECT INTERMEDIATE SHAFT SUB-ASSEMBLY 
    1. Shake the direct clutch pin and confirm that the check ball is not stuck.
    2. Apply low pressure compressed air to the check ball and confirm that there is no air leakage.
      Fig 9: Applying Low Pressure Compressed Air To Check Ball
      G04831511Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  10. INSPECT 2ND COAST AND OVERDRIVE BRAKE DISC 
    1. Check whether the contact surfaces of the discs, plates and flanges 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 the discs.
    • Before assembling new discs, soak them in ATF for at least 15 minutes.
    Fig 10: Identifying Front Clutch Disc
    G04831343Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  11. INSPECT 2ND BRAKE DISC 
    1. Check whether the contact surfaces of the discs, plates and flanges 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 the discs.
    • Before assembling new discs, soak them in ATF for at least 15 minutes.
      Fig 11: Identifying Front Clutch Disc
      G04831343Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  12. 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: 14.65 mm (0.576 in.) 

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

      Fig 12: Measuring Free Length Of Spring
      G04831493Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  13. INSPECT 1ST AND REVERSE BRAKE DISC 
    1. Check whether the contact surfaces of the discs, plates and flanges 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 the discs.
    • Before assembling new discs, soak them in ATF for at least 15 minutes.
    Fig 13: Identifying 1st And Reverse Brake Disc
    G06012368Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  14. 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: 13.96 mm (0.549 in.) 

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

      Fig 14: Measuring Free Length Of Spring
      G04831346Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  15. INSPECT DIFFERENTIAL CASE TAPERED ROLLER BEARING PRELOAD 
    1. Coat the front differential case and bearing with ATF and install them to the transaxle case.
    2. Install the transaxle housing with the 14 bolts.

      Torque: Bolt A 

      29 N*m (296 kgf*cm, 21 ft.*lbf) 

      Bolt B 

      22 N*m (224 kgf*cm, 16 ft.*lbf) 

      Fig 15: Identifying Transaxle Housing Bolts
      G06012371Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Using SST and a small torque wrench, measure the preload of the differential gear.

      SST 09564-32011 

      Preload 

      STANDARD SPECIFICATION

      Bearing Standard
      New 0.98 to 1.57 N*m (10.0 to 16.0 kgf*cm, 8.7 to 13.9 in.*lbf)
      Used 0.49 to 0.78 N*m (5.0 to 8.0 kgf*cm, 4.3 to 6.9 in.*lbf)

      If the preload is not within the specifications, remove the differential from the transaxle case.

      Select a new transaxle case side adjusting shim in accordance with the following table:

      Fig 16: Measuring Preload Of Differential Gear
      G04831349Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Adjusting Shim Thickness 

      SHIM THICKNESS CHART

      Mark Thickness mm (in.) Mark Thickness mm (in.)
      01 1.90 (0.0748) 11 2.40 (0.0945)
      02 1.95 (0.0768) 12 2.45 (0.0965)
      03 2.00 (0.0787) 13 2.50 (0.0984)
      04 2.05 (0.0807) 14 2.55 (0.1004)
      05 2.10 (0.0827) 15 2.60 (0.1024)
      06 2.15 (0.0846) 16 2.65 (0.1043)
      07 2.20 (0.0866) 17 2.70 (0.1063)
      08 2.25 (0.0885) 18 2.75 (0.1083)
      09 2.30 (0.0906) 19 2.80 (0.1102)
      10 2.35 (0.0925) - -
  16. INSPECT PACK CLEARANCE OF 1ST AND REVERSE BRAKE 
    1. Using SST and a dial indicator, measure the 1st and reverse brake clearance while pressing the discs and plates from the rear side.

      SST 09350-36010 (09350-06110) 

      Pack clearance: 

      0.81 to 1.20 mm (0.0318 to 0.0472 in.) 

      NOTE: If the clearance is not within the specified range, select a new brake flange.
      Fig 17: Inspecting Pack Clearance Of 1st And Reverse Brake
      G04831381Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      HINT:

      There are 4 different thicknesses of flanges available.

      Flange Thickness 

      FLANGE THICKNESS CHART

      Mark Thickness mm (in.) Mark Thickness mm (in.)
      - 3.4 (0.134) 2 3.8 (0.150)
      1 3.6 (0.142) 3 4.0 (0.157)
    2. Check that the 1st and reverse brake piston moves when compressed air (392 kPa, 4.0 kgf/cm2 , 57 psi) is applied to the oil hole.
  17. INSPECT NO. 2 ONE-WAY CLUTCH 
    1. Check that the rear planetary gear assembly turns freely counterclockwise and locks when turned clockwise.

    If the No. 2 one-way clutch assembly does not operate normally, replace it.

    Fig 18: Inspecting No. 2 One-Way Clutch
    G06012414Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  18. INSPECT PACK CLEARANCE OF 2ND BRAKE 
    1. Using a dial indicator, measure the 2nd brake pack clearance while applying and releasing compressed air (392 to 785 kPa, 4 to 8 kgf/cm2 , 57 to 114 psi).

      Pack clearance: 

      0.85 to 1.24 mm (0.0334 to 0.0488 in.) 

    NOTE: If the clearance is not within the specified range, select a new brake flange.
    Fig 19: Inspecting Pack Clearance Of 2nd Brake
    G04831390Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

    HINT:

    There are 4 different thicknesses of flanges available.

    Flange Thickness 

    FLANGE THICKNESS CHART

    Mark Thickness mm (in.) Mark Thickness mm (in.)
    - 3.0 (0.118) 2 3.4 (0.134)
    1 3.2 (0.126) 3 3.6 (0.142)
  19. INSPECT ONE-WAY CLUTCH ASSEMBLY 
    1. Hold the rear planetary sun gear, turn the one-way clutch and check that the one-way clutch turns freely counterclockwise and locks when turned clockwise.

    If the one-way clutch assembly does not operate normally, replace it.

    Fig 20: Inspecting One-Way Clutch Assembly
    G06012314Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  20. INSPECT PACK CLEARANCE OF REVERSE CLUTCH 
    1. Install the intermediate shaft and thrust needle roller bearing to the rear transaxle cover.
    2. Using a dial indicator, measure the reverse clutch pack clearance while applying and releasing compressed air (392 kPa, 4.0 kgf/cm2 , 57 psi).

      Pack clearance: 

      0.62 to 1.16 mm (0.0244 to 0.0456 in.) 

      NOTE: If the clearance is not within the specified range, select a new clutch flange.
      Fig 21: Inspecting Pack Clearance Of Reverse Clutch
      G04831519Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

    HINT:

    There are 4 different thicknesses of flanges available.

    Flange Thickness 

    FLANGE THICKNESS CHART

    Mark Thickness mm (in.) Mark Thickness mm (in.)
    - 3.0 (0.118) 2 3.4 (0.134)
    1 3.2 (0.126) 3 3.6 (0.142)
  21. INSPECT PACK CLEARANCE OF DIRECT CLUTCH 
    1. Install the intermediate shaft and thrust needle roller bearing to the transaxle rear cover.
    2. Using a dial indicator and measuring terminal (SST), measure the direct clutch pack clearance while applying and releasing compressed air (392 kPa, 4.0 kgf/cm2 , 57 psi).

      SST 09350-36010 (09350-06110) 

      HINT:

      The direct and reverse clutch will both move as compressed air is applied.

      Fig 22: Inspecting Pack Clearance Of Direct Clutch
      G06044749Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

    Therefore, while performing the check, press on the input shaft of the direct and reverse clutch using a press or the equivalent so that the pressure is not applied to the direct and reverse clutch.

    Pack clearance: 

    0.62 to 1.02 mm (0.0244 to 0.0402 in.) 

    NOTE: If the clearance is not within the specified range, select a new clutch flange.

    HINT:

    There are 4 different thicknesses of flanges available.

    Flange Thickness 

    FLANGE THICKNESS CHART

    Mark Thickness mm (in.) Mark Thickness mm (in.)
    - 3.0 (0.118) 2 3.4 (0.134)
    1 3.2 (0.126) 3 3.6 (0.142)
  22. INSPECT 2ND COAST AND OVERDRIVE BRAKE CLEARANCE 
    1. As shown in the illustration, place a straightedge on the transaxle case and measure the distance between the 2nd coast and overdrive brake flange and the straightedge using a vernier caliper. (Dimension B)
      Fig 23: Inspecting 2nd Coast And Overdrive Brake Clearance
      G06012438Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. As shown in the illustration, place a straightedge on the overdrive brake piston and measure the distance between the transaxle rear cover and straightedge using a vernier caliper. (Dimension C) Calculate the piston stroke value using the following formula:

      HINT:

      (Dimension A + Dimension B) - Dimension C

      Pack clearance: 

      2.10 to 2.49 mm (0.0826 to 0.0980 in.) 

      Fig 24: Measuring Distance Between Transaxle Rear Cover And Piston
      G06012439Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    NOTE: If the clearance is not within the specified range, select a new brake flange.

    HINT:

    There are 4 different thicknesses of flanges available.

    Flange Thickness 

    FLANGE THICKNESS CHART

    Mark Thickness mm (in.) Mark Thickness mm (in.)
    4 4.0 (0.1575) 6 4.4 (0.1732)
    5 4.2 (0.1654) 7 4.6 (0.1811)
  23. INSPECT INTERMEDIATE SHAFT ASSEMBLY 
    1. Install the rear transaxle cover with the 11 bolts.

      Torque: 25 N*m (255 kgf*cm, 18 ft.*lbf) 

      Fig 25: Locating Rear Transaxle Cover Bolts
      G04831293Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using a dial indicator, measure the intermediate shaft end play.

      End play: 0.21 to 0.96 mm (0.00826 to 0.0377 in.) 

      If the end play is not as specified, select and replace the rear clutch drum thrust needle roller bearing.

      HINT:

      There are 2 different thicknesses of thrust needle roller bearings available.

      Fig 26: Measuring Intermediate Shaft End Play
      G04831291Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      THICKNESS CHART

      Color Thickness mm (in.)
      Brown 0.785 (0.0309)
      Black 1.1 (0.0433)
    3. Remove the 11 bolts and the rear transaxle cover.
  24. INSPECT PACK CLEARANCE OF FORWARD CLUTCH 
    1. Using a dial indicator, measure the pack clearance while applying and releasing compressed air (392 kPa, 4.0 kgf/cm2 , 57 psi).

      Pack clearance: 

      1.41 to 1.80 mm (0.0555 to 0.0708 in.) 

      NOTE: If the clearance is not within the specified range, select a new brake flange.
    Fig 27: Inspecting Pack Clearance Of Forward Clutch
    G04831487Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

    HINT:

    There are 4 different thicknesses of flanges available.

    Flange Thickness 

    FLANGE THICKNESS CHART

    Mark Thickness mm (in.) Mark Thickness mm (in.)
    - 3.0 (0.118) 2 3.4 (0.134)
    1 3.2 (0.126) 3 3.6 (0.142)
  25. INSPECT INPUT SHAFT ASSEMBLY 
    1. Make sure that the input shaft turns smoothly.
      Fig 28: Inspecting Input Shaft Assembly
      G04831416Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  26. INSPECT INPUT SHAFT END PLAY 
  1. Measure the end play in the axial direction.

    End play: 0.38 to 1.29 mm (0.0149 to 0.0507 in.) 

    If the end play is not as specified, replace the forward clutch hub thrust needle roller bearing and the stator shaft thrust needle roller bearing.

    Fig 29: Inspecting Input Shaft End Play
    G04831284Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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