Inspection
AUTOMATIC TRANSMISSION UNITINSPECTION
1. INSPECT AUTOMATIC TRANSMISSION OIL PAN SUB-ASSEMBLY
a. Remove the magnets, and use them to collect steel particles.
b. 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): bushing wear
2. INSPECT NO. 2 1-WAY CLUTCH ASSEMBLY
a. Hold the reverse clutch hub and turn the No. 2 1way clutch assembly
b. The No. 2 1-way clutch assembly turns freely clockwise and locks when turned counterclockwise.
3. INSPECT NO. 3 BRAKE DISC
a. 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.
NOTICE: Before assembling new discs, soak them in ATF for at least 15 minutes.
4. INSPECT NO. 3 BRAKE PISTON RETURN SPRING SUB-ASSEMBLY
a. Using a vernier caliper, measure the free length of the spring together with the spring seat.
Standard free length: 15.72 mm (0.619 inch)
5. INSPECT FRONT PLANETARY GEAR ASSEMBLY
a. Using a feeler gauge, measure the front planetary pinion gear thrust clearance.
Standard clearance: 0.20 to 0.60 mm (0.0078 to 0.0236 inch)
Maximum clearance: 0.65 mm (0.0256 inch)
If the clearance is greater than the maximum, replace the front planetary gear assembly
b. Using a dial indicator, measure the inside diameter of the front planetary gear bushing.
Maximum inside diameter: 57.48 mm (2.2630 inch)
If the inside diameter is greater than the maximum, replace the front planetary gear.
6. INSPECT 1-WAY CLUTCH ASSEMBLY
a. Install the 1-way clutch assembly to the 1-way clutch inner race.
b. Hold the 1-way clutch inner race and turn the 1-way clutch assembly
c. Check that the 1-way clutch assembly turns freely counterclockwise and locks when turned clockwise.
d. Remove the 1-way clutch assembly from 1-way clutch inner race.
7. INSPECT NO. 1 BRAKE DISC
a. 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.
NOTICE: Before assembling new discs, soak them in ATF for at least 15 minutes.
8. INSPECT BRAKE PISTON RETURN SPRING SUB-ASSEMBLY
a. Using a vernier caliper, measure the free length of the spring together with the spring seat.
Standard free length: 17.05 mm (0.6713 inch)
9. INSPECT NO. 2 BRAKE DISC
a. Check whether the sliding surface of the disc, the plate and the flange are worn or burnt.
If necessary, replace them.
NOTICE:
^ If the lining of the disc is peeled off or discolor, or even if only a part of the print numbers is damaged, replace all discs.
^ Before assembling new discs, soak them in ATF for at least 15 minutes.
10. INSPECT NO. 2 BRAKE PISTON RETURN SPRING SUB-ASSEMBLY
a. Using a vernier caliper, measure the free length of the spring together with the spring seat.
Standard free length: 17.45 mm (0.6870 inch)
11. INSPECT CENTER PLANETARY GEAR ASSEMBLY
a. Using a feeler gauge, measure the center planetary gear pinion thrust clearance.
Standard clearance: 0.12 to 0.68 mm (0.0047 to 0.0268 inch)
Maximum clearance: 0.73 mm (0.0287 inch)
If the clearance is greater than the maximum, replace the center planetary gear assembly
12. INSPECT NO. 3 1-WAY CLUTCH ASSEMBLY
a. Hold the rear planetary ring gear flange sub assembly, and then turn the 1-way clutch assembly
b. Check that the 1-way clutch assembly turns freely counterclockwise and locks when turned clockwise.
13. INSPECT REAR PLANETARY RING GEAR FLANGE SUB-ASSEMBLY
a. Using a caliper gauge, measure the inside diameter of the rear planetary ring gear bushing.
Maximum inside diameter: 32.175 mm (1.2667 inch)
If the inside diameter is greater than the maximum, replace the rear planetary ring gear.
14. INSPECT INTERMEDIATE SHAFT
a. Using a dial indicator, check the intermediate shaft runout.
Maximum runout: 0.08 mm (0.0031 inch)
If the runout exceeds the specification, replace the intermediate shaft with a new one.
b. 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 (1.0221 to 1.026 inch)
B: 25.962 to 25.975 mm (1.0221 to 1.026 inch)
C: 32.062 to 32.075 mm (1.262 to 1.2627 inch)
D: 32.062 to 32.075 mm (1.2622 to 1.2627 inch)
Standard diameter:
A: 25.912 mm (1.0202 inch)
B: 25.912 mm (1.0202 inch)
C: 32.012 mm (1.2603 inch)
D: 32.012 mm (1.2603 inch)
If the outer diameter is outside the standard, replace the intermediate shaft with the a new one.
15. INSPECT NO. 4 BRAKE DISC
a. 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.
NOTICE: Before assembling new discs, soak them in ATF for at least 15 minutes.
16. INSPECT REAR PLANETARY GEAR ASSEMBLY
a. 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 inch)
Maximum clearance: 0.65 mm (0.0256 inch)
If the clearance is greater than the maximum, replace the planetary gear assembly
b. Using a caliper gauge, measure the inside diameter of the rear planetary gear bushing.
Maximum inside diameter: 20.075 mm (0.7904 inch)
If the inside diameter is greater than the maximum, replace the rear planetary gear assembly.
17. INSPECT 1ST AND REVERSE BRAKE RETURN SPRING SUB-ASSEMBLY
a. Using a vernier caliper, measure the free length of the spring together with the spring seat.
Standard free length: 23.74 mm (0.9346 inch)
18. INSPECT PACK CLEARANCE OF FIRST AND REVERSE BRAKE
a. Make sure the 1st and reverse brake pistons move smoothly when applying and releasing the compressed air into the transmission case.
19. INSPECT PISTON STROKE OF NO. 1 BRAKE PISTON
a. Make sure the No. 1 brake piston moves smoothly when applying and releasing the compressed air into the transmission case.
b. Using a feeler gauge, measure the B3 brake pack clearance between the snap ring and flange.
Piston stroke: 0.42 to 0.72 mm (0.0165 to 0.0283 inch)
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.
Standard Flange Thickness:
20. INSPECT INDIVIDUAL PISTON OPERATION INSPECTION
a. Check the operating sound while applying compressed air into the oil holes indicated in the illustration.
HINT: When inspecting the O/D 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)