AUTOMATIC TRANSAXLE UNIT INSPECTION
1. INSPECT TRANSMISSION OIL CLEANER MAGNET
a. Examine particles in the automatic transaxle oil pan sub-assembly.
i. Collect any steel chips with the
removed magnets. Look carefully
at the chips and particles in the
automatic transaxle oil pan sub-
assembly and on the transmission
oil cleaner magnets to see the type
of wear which might be found in
the automatic transaxle assembly.
Result
Brass (non-
Steel (magnetic)
magnetic)
Bearing, gear and
Bushing wear
plate wear
2. INSPECT INPUT SHAFT END PLAY
a. Using a dial indicator, measure the input
shaft end play.
Standard end play
0.020 to 1.242 mm (0.000788 to 0.0488
in.)
3. INSPECT INTERMEDIATE SHAFT END PLAY
a. Clean the contact surfaces of the transaxle
case sub-assembly and rear transaxle
cover sub-assembly.
b. As shown in the illustration, place a
straightedge on the multiple direct clutch
drum and measure the distance between
the transaxle case sub-assembly and the
straightedge using a vernier caliper
(Dimension A).
Text in Illustration
*a Dimension A
c. Using a vernier caliper and a straightedge,
measure the distance shown in the
illustration (Dimension B).
d. Calculate the end play value using the
following formula:
End play = Dimension B - Dimension A -
Thrust needle roller bearing thickness
Standard end play
0.022 to 1.099 mm (0.000867 to 0.0432
in.)
Text in Illustration
*a Dimension B
4. INSPECT PLANETARY SUN GEAR SUB-ASSEMBLY
a. Using a caliper gauge, measure the inside
diameter of the bushings of the planetary
sun gear.
Standard inside diameter
25.525 to 25.546 mm (1.00492 to 1.00575
in.)
Maximum inside diameter
25.546 mm (1.00575 in.)
If the inside diameter is greater than the
maximum, replace the planetary sun gear.
5. INSPECT REAR PLANETARY SUN GEAR ASSEMBLY
a. Using a caliper gauge, measure the inside diameter of the bushing of the rear planetary sun
gear sub-assembly.
Standard inside diameter
25.580 to 25.601 mm (1.00708 to 1.00791 in.)
Maximum inside diameter
25.601 mm (1.00791 in.)
If the inside diameter is greater than the maximum, replace the automatic transaxle assembly.
6. INSPECT UNDERDRIVE PLANETARY GEAR ASSEMBLY
a. Using a feeler gauge, measure the
clearance between the underdrive
planetary gear and the pinion gear at 4
points.
Standard clearance
0.18 to 0.54 mm (0.00709 to 0.0213 in.)
If the clearance is greater than the
standard clearance, replace the automatic
transaxle assembly.
7. INSPECT ONE-WAY CLUTCH ASSEMBLY
a. Temporarily install the one-way clutch
assembly to the planetary ring gear.
b. Make sure that the one-way clutch
assembly turns freely counterclockwise
and locks when turned clockwise.
If the one-way clutch assembly does not
operate normally, replace it.
Text in Illustration
*1 Planetary Ring Gear
*2 One-way Clutch Assembly
*a Free
*b Lock
8. INSPECT NO. 1 BRAKE DISC
a. Check if the contact surfaces of the discs,
plates and flange are worn or burnt.
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.
If necessary, replace them.
9. INSPECT NO. 2 BRAKE DISC
a. Check if the contact surfaces of the discs,
plates and flange are worn or burnt.
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.
If necessary, replace them.
10. INSPECT NO. 3 BRAKE DISC
a. Check if the contact surfaces of the discs,
plates and flanges are worn or burnt.
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.
If necessary, replace them.
11. INSPECT 2ND BRAKE PISTON RETURN SPRING SUB-ASSEMBLY
a. Using a vernier caliper, measure the free
length of the 3 2nd brake piston return
springs including the spring seats.
Standard free length
23.26 mm (0.916 in.)
If the free length is shorter than the
standard free length, replace the 2nd
brake piston return spring.
12. INSPECT 1ST AND REVERSE BRAKE RETURN SPRING SUB-ASSEMBLY
a. Using a vernier caliper, measure the free
length of the 1st and reverse brake return
spring together with the spring seat.
Standard free length
15.79 mm (0.622 in.)
If the free length is shorter than the
standard free length, replace the 1st and
reverse brake return spring.
13. INSPECT NO. 3 BRAKE PISTON RETURN SPRING SUB-ASSEMBLY
a. Using a vernier caliper, measure the free
length of the No. 3 brake piston return
spring together with the spring seat.
Standard free length
9.15 mm (0.360 in.)
If the free length is shorter than the
standard free length, replace the No. 3
brake piston return spring.
14. INSPECT CLEARANCE OF NO. 1 BRAKE
a. Using a dial indicator, measure the
clearance of the No. 1 brake while
applying compressed air (200 kPa, 2.0
kgf/cm2, 29 psi).
Standard clearance
0.601 to 0.819 mm (0.0237 to 0.0322 in.)
Tech Tips
Measure the clearance at 3 points where the
brake piston diameter is approximately 140
mm (5.51 in.) and calculate the average.
If the clearance is not as specified, select
an appropriate No. 1 brake flange so that
the clearance will be within the specified
range.
No. 1 Brake Flange
Thickness
Mark Thickness [mm (in.)]
30 3.0 (0.118)
31 3.1 (0.122)
32 3.2 (0.126)
33 3.3 (0.130)
34 3.4 (0.134)
35 3.5 (0.138)
15. INSPECT CLEARANCE OF NO. 2 BRAKE
a. Using a dial indicator, measure the
clearance of the No. 2 brake while
applying compressed air (200 kPa, 2.0
kgf/cm2, 29 psi).
Standard clearance
0.707 to 0.974 mm (0.0278 to 0.0383 in.)
Tech Tips
Measure the clearance at 3 points where the
brake piston diameter is approximately 140
mm (5.51 in.) and calculate the average.
If the clearance is not as specified, select
an appropriate No. 2 brake flange so that
the clearance will be within the specified
range.
No. 2 Brake Flange
Thickness
Mark Thickness [mm (in.)]
40 4.0 (0.157)
41 4.1 (0.161)
42 4.2 (0.165)
43 4.3 (0.169)
44 4.4 (0.173)
16. INSPECT CLEARANCE OF NO. 3 BRAKE
a. Using a vernier caliper and a straightedge,
measure the distance shown in the
illustration (Dimension A) while a load of
500 N (51 kgf, 112.4 lbf) is being applied
to the flange.
Tech Tips
Measure dimension A at 3 points where the
flange diameter is approximately 166 mm
(6.54 in.) and calculate the average.
b. Using a vernier caliper and a straightedge,
measure the distance shown in the
illustration (Dimension B).
Tech Tips
Measure dimension B at 3 points where the
No. 3 brake diameter is approximately 166 mm
(6.54 in.) and calculate the average.
c. Calculate the clearance value using the
following formula:
Clearance = Dimension B - Dimension A -
Flange Thickness
Standard clearance
0.599 to 0.799 mm (0.0236 to 0.0315 in.)
If the clearance is not as specified, select
an appropriate brake flange so that the
clearance will be within the specified
range.
No. 3 Brake Flange
Thickness
Mark Thickness [mm (in.)]
38 3.80 (0.150)
39 3.90 (0.154)
40 4.00 (0.157)
41 4.10 (0.161)
42 4.20 (0.165)
43 4.30 (0.169)
Text in Illustration
*1 Front Oil Pump Assembly
*2 No. 3 Brake
*a Dimension A
*b Dimension B
*c Contact Surface of Front Oil Pump Assembly
17. INSPECT CLEARANCE OF NO. 1 CLUTCH
a. Install the direct multiple disc clutch
assembly onto the rear transaxle cover
sub-assembly.
b. Check that the piston moves when
compressed air (200 kPa, 2.0 kgf/cm2, 29
psi) is applied to the oil hole.
c. Using a feeler gauge, measure the No. 1
clutch pack clearance.
Tech Tips
Measure the clearance at 3 points where the
flange diameter is approximately 152 mm
(5.98 in.) and calculate the average.
Standard pack clearance
0.601 to 0.819 mm (0.0237 to 0.0322 in.)
If the pack clearance is not as specified,
replace the rear multiple disc clutch
assembly.
Text in Illustration
*1 Feeler Gauge
18. INSPECT CLEARANCE OF NO. 2 CLUTCH
a. Install the direct multiple disc clutch
assembly onto the rear transaxle cover
sub-assembly.
b. Using a dial indicator, measure the No. 2
clutch pack clearance while applying and
releasing compressed air (200 kPa, 2.0
kgf/cm2, 29 psi).
Tech Tips
Measure the clearance at 3 points where the
diameter of the No. 2 direct multiple clutch
piston is approximately 152 mm (5.98 in.) and
calculate the average.
Standard pack clearance
0.394 to 0.605 mm (0.0155 to 0.0238 in.)
If the pack clearance is not as specified,
replace the rear multiple disc clutch
assembly.
