2-6 BRAKE CLEARANCE MEASUREMENT/ADJUSTMENT

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Preparation Before Servicing

1. Print out the measurement/adjustment value input sheet. (See MEASUREMENT/ADJUSTMENT VALUE INPUT SHEET.)

Note

• When performing the measurement/adjustment, input the measured and calculated values into the measurement/adjustment value input sheet.

• If the measurement/adjustment value input sheet has already been printed out for the other measurements/adjustments, use the sheet.

2-6 Brake Clearance Measurement

1. Set the end cover with the assembled part on the workbench as shown in the figure.

Caution

• To reduce measurement differences during the 2-6 brake clearance measurement, use the rubber plates to adjust the alignment surface of the end cover with the transaxle case so that it is level.

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A :Rubber plate

2. Assemble the retaining plate.

Note

• Retaining plate size: Inner diameter approx. 137.2 mm {5.402 in}

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3. Assemble the 2-6 brake piston to the brake housing using the following procedure:

(1) Apply ATF (ATF FZ) to the 2-6 brake piston lip.

(2) Assemble the 2-6 brake piston.

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4. Measure distance A shown in the figure of the assembled parts from Step 3 and calculate the average value of distance A.

Note

• Recommended measuring instrument: Depth micrometer, straight edge ruler

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A :Distance A

B :2-6 brake piston end

C :Brake housing end (alignment surface with end cover)

(1) Measure the thickness of the straight edge ruler.

Note

• Recommended measuring instrument: Micrometer

(2) Input the measured straight edge ruler thickness into the measurement/adjustment value input sheet.

(3) Set two straight edge rulers on the 2-6 brake piston as shown in the figure.

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A :Straight edge ruler

(4) Measure the positions in 3 locations (each separated by 120°) shown in the figure and subtract the thickness of the straight edge ruler from distance A.

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A :Straight edge ruler

(5) Input distance A and the average value of distance A into the measurement/adjustment value input sheet.

5. Install the SSTs.

Caution

• Install the SST (49 D019 009) so that the end with the large diameter is pointing towards the retaining plate.

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6. Measure distance B shown in the figure at the four locations (each separated by 120°) and calculate the average value of distance B.

Note

• Recommended measuring instrument: Depth micrometer

• Measure the splines of the retaining plate using a depth micrometer.

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A :Distance B

B :End cover end (alignment surface with brake housing)

C :Retaining plate end

7. Input the measured distance B and calculated distance B average value into the measurement/adjustment value input sheet.

8. Perform the following calculation to calculate the 2-6 brake clearance.

2-6 Brake Clearance = E - C

C: Average value of distance A

E: Average value of distance B

Note

Example

C: Average value of distance A is 3.150 mm {0.1240 in}

E: Average value of distance B is 4.370 mm {0.1720 in}

2-6 brake clearance = 4.370 mm {0.1720 in} - 3.150 mm {0.1240 in}= 1.220 mm {0.04803 in}

9. Input the calculated 2-6 brake clearance into the measurement/adjustment value input sheet.

10. Verify that the 2-6 brake clearance satisfies the specification.

Specification

1.000—1.200 mm {0.03938—0.04724 in}

• If not within the specification, adjust the 2-6 brake clearance. (See 2-6 Brake Clearance Adjustment.)

11. Remove the SSTs.

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12. Take the end cover off the rubber plates.

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2-6 Brake Clearance Adjustment

1. Remove the SSTs.

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2. Remove the retaining plate.

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3. Measure the thickness of the removed retaining plate.

Note

• Recommended measuring instrument: Micrometer

4. Input the measured retaining plate thickness into the measurement/adjustment value input sheet.

5. Perform the following calculation to calculate the 2-6 brake clearance gap.

Note

• The 2-6 brake clearance gap is the difference between the 2-6 brake clearance and the median value of the 2-6 brake clearance specification.

2-6 brake clearance gap = F-J

F: 2-6 brake clearance

J: 2-6 brake clearance specification median value (1.100 mm {0.04331 in})

Note

Example

F: 2-6 brake clearance is 1.220 mm {0.04803 in}

2-6 brake clearance gap = 1.220 mm {0.04803 in} - 1.100 mm {0.04331 in}= 0.120 mm {0.00472 in}

6. Input the calculated 2-6 brake clearance gap into the measurement/adjustment value input sheet.

7. Perform the following calculation to calculate the optimum retaining plate thickness.

Thickness of optimum retaining plate = I + K

I: Thickness of removed retaining plate

K: 2-6 brake clearance gap

Note

Example

I: Thickness of removed retaining plate is 1.615 mm {0.06358 in}

Thickness of optimum retaining plate = 1.615 mm {0.06358 in}+ 0.120 mm {0.00472 in}= 1.735 mm {0.06831 in}

8. Input the calculated optimum retaining plate thickness into the measurement/adjustment value input sheet.

9. From the following table, select a retaining plate of a thickness closest to the calculated optimum thrust retaining plate.

Retaining plate thickness

2.2 mm {0.087 in}

2.1 mm {0.083 in}

2.0 mm {0.079 in}

1.9 mm {0.075 in}

1.8 mm {0.071 in}

1.7 mm {0.067 in}

1.6 mm {0.063 in}

Retaining plate thickness
2.2 mm {0.087 in}
2.1 mm {0.083 in}
2.0 mm {0.079 in}
1.9 mm {0.075 in}
1.8 mm {0.071 in}
1.7 mm {0.067 in}
1.6 mm {0.063 in}

10. Assemble the selected retaining plate.

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11. Perform the 2-6 brake clearance measurement from Step 5. (See 2-6 Brake Clearance Measurement.)