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Inspection [09/2015 - ]: Procedure

  1. INSPECT NO. 1 BRAKE DISC 
    1. Check whether the sliding surfaces of the No. 1 brake discs, No. 1 brake plates and the No. 1 brake flange are worn or burnt.
      GTY598937Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:
      • If the linings of the No. 1 brake discs are peeled off or discolored, or if any part of the printed numbers is damaged, replace all the No. 1 brake discs.
      • Before assembling new No. 1 brake discs, soak them in ATF for at least 2 hours.

      If necessary, replace them.

  2. INSPECT FRONT PLANETARY GEAR ASSEMBLY 
    1. Using a feeler gauge, measure the clearance between the front planetary gear assembly and each pinion gear.
      GTY107421Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Standard Clearance

      0.2 to 0.6 mm (0.00788 to 0.0236 in.)

      If the clearance is not as specified, replace the front planetary gear assembly.

  3. INSPECT PACK CLEARANCE OF NO. 1 BRAKE 
    1. Using a vernier caliper, measure dimension A (from the step of the oil pump assembly installation surface of the automatic transmission case sub-assembly to the step of the No. 1 brake flange installation surface) in the illustration, and calculate the average.
      GTY624315Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      *1 Snap Ring

      HINT: 

      Dimension A = 46.18 to 46.54 mm (1.8182 to 1.8322 in.)

    2. Using a vernier caliper, measure dimension B (from the flange face of the oil pump assembly to the tip of the No. 1 brake piston) in the illustration, and calculate the average.
      GTY542985Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      HINT: 

      Dimension B = 19.23 to 19.57 mm (0.7571 to 0.7704 in.)

    3. Using a vernier caliper, assemble the 6 No. 1 brake plates, 6 No. 1 brake discs and No. 1 brake flange, measure dimension C in the illustration and calculate the average.
      GTY598556Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      *1 No. 1 Brake Flange
      *2 No. 1 Brake Disc
      *3 No. 1 Brake Plate

      HINT: 

      • Dimension C = 25.15 to 26.45 mm (0.9902 to 1.0413 in.)
      • Pack clearance = Dimension A - Dimension B - Dimension C

      Standard Clearance

      0.90 to 1.10 mm (0.0355 to 0.0433 in.)

    4. If the pack clearance is outside the standard range, select and install a No. 1 brake flange that brings the pack clearance within the standard range.

      HINT: 

      There are 7 types of No. 1 brake flanges that can be used to adjust the pack clearance. Select the one with the most appropriate thickness.

      No. 1 Brake Flange Thickness

      Part No. Mark Thickness
      35676-60190 0 4.45 to 4.55 mm (0.1752 to 0.1791 in.)
      35676-60200 1 4.55 to 4.65 mm (0.1792 to 0.1830 in.)
      35676-60210 2 4.65 to 4.75 mm (0.1831 to 0.1870 in.)
      35676-60220 3 4.75 to 4.85 mm (0.1871 to 0.1909 in.)
      35676-60230 4 4.85 to 4.95 mm (0.1910 to 0.1948 in.)
      35676-60240 5 4.95 to 5.05 mm (0.1949 to 0.1988 in.)
      35676-60250 6 5.05 to 5.15 mm (0.1989 to 0.2027 in.)
  4. INSPECT NO. 3 CLUTCH DISC 
    1. Check whether the sliding surfaces of the No. 3 clutch discs, No. 3 clutch plates and the No. 3 clutch flange are worn or burnt.
      GTY545031Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:
      • If the linings of the No. 3 clutch discs are peeled off or discolored, or if any part of the printed numbers is damaged, replace all the No. 3 clutch discs.
      • Before assembling new No. 3 clutch discs, soak them in ATF for at least 2 hours.

      If necessary, replace them.

  5. INSPECT PACK CLEARANCE OF NO. 3 CLUTCH 
    1. Using a dial indicator, measure the moving distance (distance A) of the No. 3 clutch flange at both ends across the diameter while blowing compressed air (196 kPa, 2.0 kgf/cm2 , 28 psi) from the oil hole as shown in the illustration, and calculate the average.
      GTY626037Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      *a Oil Hole *b Distance A
      *c Speed Sensor Hole - -

      Standard Clearance

      0.90 to 1.10 mm (0.0355 to 0.0433 in.)

    2. If the pack clearance is outside the standard range, select and install a No. 3 clutch flange that brings the pack clearance within the standard range.

      HINT: 

      There are 11 types of No. 3 clutch flanges that can be used to adjust the pack clearance. Select the one with the most appropriate thickness.

      No. 3 Clutch Flange Thickness

      Part No. Thickness
      34649-60250 3.75 to 3.85 mm (0.1477 to 0.1515 in.)
      34649-60260 3.85 to 3.95 mm (0.1516 to 0.1555 in.)
      34649-60270 3.95 to 4.05 mm (0.1556 to 0.1594 in.)
      34649-60280 4.05 to 4.15 mm (0.1595 to 0.1633 in.)
      34649-60290 4.15 to 4.25 mm (0.1634 to 0.1673 in.)
      34649-60300 4.25 to 4.35 mm (0.1674 to 0.1712 in.)
      34649-60310 4.35 to 4.45 mm (0.1713 to 0.1751 in.)
      34649-60320 4.45 to 4.55 mm (0.1752 to 0.1791 in.)
      34649-60330 4.55 to 4.65 mm (0.1792 to 0.1830 in.)
      34649-60340 4.65 to 4.75 mm (0.1831 to 0.1870 in.)
      34649-60350 4.75 to 4.85 mm (0.1871 to 0.1909 in.)
  6. INSPECT OVERDRIVE DIRECT CLUTCH DISC 
    1. Check whether the sliding surfaces of the overdrive direct clutch discs, overdrive direct clutch plates and the overdrive clutch flange are worn or burnt.
      GTY545030Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:
      • If the linings of the overdrive direct clutch discs are peeled off or discolored, or if any part of the printed numbers is damaged, replace all the overdrive direct clutch discs.
      • Before assembling new overdrive direct clutch discs, soak them in ATF for at least 2 hours.

      If necessary, replace them.

  7. INSPECT REVERSE CLUTCH RETURN SPRING SUB-ASSEMBLY (REAR) 
    1. Using a vernier caliper, measure the free length of the spring together with the spring seat.
      GTY100646Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Standard Free Length

      22.21 mm (0.874 in.)

      If the free length is shorter than the standard free length, replace the reverse clutch return spring sub-assembly (rear).

  8. INSPECT PACK CLEARANCE OF OVERDRIVE DIRECT CLUTCH 
    1. Using a dial indicator, measure the moving distance (distance A) of the reverse clutch flange at both ends across the diameter while blowing compressed air (300 kPa, 3.1 kgf/cm2 , 44 psi) from the oil hole as shown in the illustration, and calculate the average.
      GTY662953Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      *a Oil Hole *b Distance A
      *c Speed Sensor Hole - -

      Standard Clearance

      1.19 to 1.39 mm (0.0469 to 0.0547 in.)

    2. If the pack clearance is outside the standard range, select and install a overdrive clutch flange that brings the pack clearance within the standard range.

      HINT: 

      There are 11 types of overdrive clutch flanges that can be used to adjust the pack clearance. Select the one with the most appropriate thickness.

      Overdrive Clutch Flange Thickness

      Part No. Thickness
      34615-60010 2.85 to 2.95 mm (0.1123 to 0.1161 in.)
      34615-60020 2.95 to 3.05 mm (0.1162 to 0.1200 in.)
      34615-60030 3.05 to 3.15 mm (0.1201 to 0.1240 in.)
      34615-60040 3.15 to 3.25 mm (0.1241 to 0.1279 in.)
      34615-60050 3.25 to 3.35 mm (0.1280 to 0.1318 in.)
      34615-60060 3.35 to 3.45 mm (0.1319 to 0.1358 in.)
      34615-60070 3.45 to 3.55 mm (0.1359 to 0.1397 in.)
      34615-60080 3.55 to 3.65 mm (0.1398 to 0.1437 in.)
      34615-60090 3.65 to 3.75 mm (0.1438 to 0.1476 in.)
      34615-60100 3.75 to 3.85 mm (0.1477 to 0.1515 in.)
      34615-60110 3.85 to 3.95 mm (0.1516 to 0.1555 in.)
  9. INSPECT REVERSE CLUTCH RETURN SPRING SUB-ASSEMBLY (FRONT) 
    1. Using a vernier caliper, measure the free length of the spring together with the spring seat.
      GTY107414Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Standard Free Length

      21.59 mm (0.850 in.)

      If the free length is shorter than the standard free length, replace the reverse clutch return spring sub-assembly (front).

  10. INSPECT REVERSE CLUTCH DRUM SUB-ASSEMBLY 
    1. Using a caliper gauge, measure the inside diameter of the reverse clutch drum sub-assembly bush.
      GTY545053Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Standard Inside Diameter (Front Side)

      67.40 to 67.44 mm (2.6536 to 2.6551 in.)

      Standard Inside Diameter (Rear Side)

      55.62 to 55.64 mm (2.1898 to 2.1905 in.)

      If the inside diameter is not as specified, replace the reverse clutch drum sub-assembly.

  11. INSPECT FORWARD MULTIPLE CLUTCH DISC 
    1. Check whether the sliding surfaces of the forward multiple clutch discs, forward multiple clutch plates and forward clutch flange are worn or burnt.
      GTY598942Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:
      • If the linings of the forward multiple clutch discs are peeled off or discolored, replace all the forward multiple clutch discs.
      • Before assembling new forward multiple clutch discs, soak them in ATF for at least 2 hours.

      If necessary, replace them.

  12. INSPECT FORWARD CLUTCH RETURN SPRING SUB-ASSEMBLY 
    1. Using a vernier caliper, measure the free length of the spring together with the spring seat.
      GTY107416Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Standard Free Length

      20.82 mm (0.820 in.)

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

  13. INSPECT PACK CLEARANCE OF FORWARD MULTIPLE CLUTCH 
    1. Temporarily assemble the front planetary gear assembly to the forward clutch drum sub-assembly.
    2. Using a dial indicator, measure the moving distance (distance A) of the forward clutch flange at both ends across the diameter while blowing compressed air (196 kPa, 2.0 kgf/cm2 , 28 psi) from the oil hole as shown in the illustration, and calculate the average.
      GTY594135Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      *a Oil Hole
      *b Distance A

      Standard Clearance

      1.05 to 1.25 mm (0.0414 to 0.0492 in.)

    3. If the pack clearance is outside the standard range, select and install a forward clutch flange that brings the pack clearance within the standard range.

      HINT: 

      There are 9 types of forward clutch flanges that can be used to adjust the pack clearance. Select the one with the most appropriate thickness.

      Forward Clutch Flange Thickness

      Part No. Mark Thickness
      35635-50090 0 4.35 to 4.45 mm (0.1713 to 0.1751 in.)
      35635-50100 1 4.45 to 4.55 mm (0.1752 to 0.1791 in.)
      35635-50110 2 4.55 to 4.65 mm (0.1792 to 0.1830 in.)
      35635-50120 3 4.65 to 4.75 mm (0.1831 to 0.1870 in.)
      35635-50130 4 4.75 to 4.85 mm (0.1871 to 0.1909 in.)
      35635-50140 5 4.85 to 4.95 mm (0.1910 to 0.1948 in.)
      35635-50150 6 4.95 to 5.05 mm (0.1949 to 0.1988 in.)
      35635-50160 7 5.05 to 5.15 mm (0.1989 to 0.2027 in.)
      35635-50170 8 5.15 to 5.25 mm (0.2028 to 0.2066 in.)
  14. INSPECT FORWARD CLUTCH DRUM SUB-ASSEMBLY 
    1. Using a caliper gauge, measure the inside diameter of the forward clutch drum bush.
      GTY107423Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Standard Inside Diameter

      33.200 to 33.225 mm (1.3071 to 1.3080 in.)

      If the inside diameter is not as specified, replace the forward clutch drum sub-assembly.

  15. INSPECT SUN GEAR INPUT DRUM SUB-ASSEMBLY 
    1. Using a caliper gauge, measure the inside diameter of the sun gear input drum bush.
      GTY107424Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Standard Inside Diameter

      45.066 to 45.091 mm (1.7743 to 1.7752 in.)

      If the inside diameter is not as specified, replace the sun gear input drum sub-assembly.

  16. INSPECT REAR PLANETARY SUN GEAR SUB-ASSEMBLY 
    1. Using a caliper gauge, measure the inside diameter of the rear planetary sun gear bush.
      GTY107425Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Standard Inside Diameter

      28.760 to 28.781 mm (1.1323 to 1.1331 in.)

      If the inside diameter is not as specified, replace the rear planetary sun gear sub-assembly.

  17. INSPECT REAR PLANETARY GEAR ASSEMBLY 
    1. Using a feeler gauge, measure the rear planetary gear pinion long and short thrust clearance.
      GTY107422Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Standard Clearance

      0.2 to 0.6 mm (0.00788 to 0.0236 in.)

      If the clearance is not as specified, replace the rear planetary gear assembly.

    2. Using a caliper gauge, measure the inside diameter of the rear planetary gear bush.
      GTY100638Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Standard Inside Diameter (Front Side)

      70.60 to 70.63 mm (2.7796 to 2.7807 in.)

      Standard Inside Diameter (Rear Side)

      28.700 to 28.721 mm (1.1300 to 1.1307 in.)

      If the inside diameter is not as specified, replace the rear planetary gear assembly.

  18. INSPECT NO. 1 ONE-WAY CLUTCH 
    1. Install the No. 1 one-way clutch to the rear planetary gear assembly.
    2. Hold the rear planetary gear assembly and turn the No. 1 one-way clutch.
      GTY580745Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      Lock
      Free
    3. Check that the No. 1 one-way clutch turns freely counterclockwise and locks clockwise.

      If the No. 1 one-way clutch does not operate normally, replace it.

  19. INSPECT NO. 2 BRAKE DISC 
    1. Check whether the sliding surfaces of the No. 2 brake discs, brake plate, No. 2 brake plates and the No. 2 brake flange are worn or burnt.
      GTY545055Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:
      • If the linings of the No. 2 brake discs are peeled off or discolored, or if any part of the printed numbers is damaged, replace all the No. 2 brake discs.
      • Before assembling new discs, soak them in ATF for at least 2 hours.

      If necessary, replace them.

  20. INSPECT NO. 2 CLUTCH DISC 
    1. Check whether the sliding surfaces of the No. 2 clutch discs, No. 2 clutch plates and the No. 2 clutch flange are worn or burnt.
      GTY598943Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:
      • If the linings of the No. 2 clutch discs are peeled off or discolored, replace all the No. 2 clutch discs.
      • Before assembling new discs, soak them in ATF for at least 2 hours.

      If necessary, replace them.

  21. 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.
      GTY107417Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Standard Free Length

      23.36 mm (0.920 in.)

      If the free length is shorter than the standard free length, replace the No. 2 brake piston return spring sub-assembly.

  22. INSPECT PACK CLEARANCE OF NO. 2 BRAKE 
    1. Using a vernier caliper, measure dimension A (from the tip of the No. 2 brake piston to the step in the automatic transmission case sub-assembly) in the illustration, and calculate the average.
      GTY541216Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      *1 Snap Ring

      HINT: 

      Dimension A = 35.75 to 36.25 mm (1.4075 to 1.4271 in.)

    2. Using a vernier caliper, assemble the 6 No. 2 brakes discs, brake plate, 5 No. 2 brake plates and No. 2 brake flange as shown in the illustration. Then with a weight fixture of 500 g (17.64 oz) or less placed on the flange, measure dimension B, and calculate the average.
      GTY616445Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      *1 No. 2 Brake Flange
      *2 Brake Plate
      *3 No. 2 Brake Plate
      *4 No. 2 Brake Disc
      *a Weight

      HINT: 

      • Dimension B = 33.73 to 35.07 mm (1.3280 to 1.3807 in.)
      • Pack clearance = Dimension A - Dimension B

      Standard Clearance

      0.90 to 2.18 mm (0.0355 to 0.0858 in.)

    3. If the pack clearance is outside the standard range, select and install a No. 2 brake flange that brings the pack clearance within the standard range.

      HINT: 

      There are 11 types of No. 2 brake flanges that can be used to adjust the pack clearance. Select the one with the most appropriate thickness.

      No. 2 Brake Flange Thickness

      Part No. Mark Thickness
      35678-60190
      GTY548011Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      		 9.75 to 9.85 mm (0.3839 to 0.3877 in.)
      35678-60200
      GTY548013Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      		 9.85 to 9.95 mm (0.3878 to 0.3917 in.)
      35678-60210
      GTY548014Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      		 9.95 to 10.05 mm (0.3918 to 0.3956 in.)
      35678-60220
      GTY548015Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      		 10.05 to 10.15 mm (0.3957 to 0.3996 in.)
      35678-60230
      GTY548009Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      		 10.15 to 10.25 mm (0.3997 to 0.4035 in.)
      35678-60240
      GTY548010Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      		 10.25 to 10.35 mm (0.4036 to 0.4074 in.)
      35678-60250
      GTY548060Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      		 10.35 to 10.45 mm (0.4075 to 0.4114 in.)
      35678-60260
      GTY548053Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      		 10.45 to 10.55 mm (0.4115 to 0.4153 in.)
      35678-60270
      GTY599611Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      		 10.55 to 10.65 mm (0.4154 to 0.4192 in.)
      35678-60280
      GTY548055Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      		 10.65 to 10.75 mm (0.4193 to 0.4232 in.)
      35678-60290
      GTY548056Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      		 10.75 to 10.85 mm (0.4233 to 0.4271 in.)
  23. INSPECT DIRECT CLUTCH RETURN SPRING SUB-ASSEMBLY 
    1. Using a vernier caliper, measure the free length of the spring together with the spring seat.
      GTY100647Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Standard Free Length

      20.76 mm (0.817 in.)

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

  24. INSPECT PACK CLEARANCE OF NO. 2 CLUTCH 
    1. Using a dial indicator, measure the moving distance (distance A) of the No. 2 clutch flange at both ends across the diameter while blowing compressed air (196 kPa, 2.0 kgf/cm2 , 28 psi) from the oil hole as shown in the illustration, and calculate the average.
      GTY638183Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Standard Clearance

      1.05 to 1.25 mm (0.0414 to 0.0492 in.)

      TEXT IN ILLUSTRATION

      *a Oil Hole
      *b Distance A
    2. If the pack clearance is outside the standard range, select and install a No. 2 clutch flange that brings the pack clearance within the standard range.

      HINT: 

      There are 9 types of No. 2 clutch flanges that can be used to adjust the pack clearance. Select the one with the most appropriate thickness.

      No. 2 Clutch Flange Thickness

      Part No. Mark Thickness
      35635-50181 40 3.95 to 4.05 mm (0.1556 to 0.1594 in.)
      35635-50231 41 4.05 to 4.15 mm (0.1595 to 0.1633 in.)
      35635-50191 42 4.15 to 4.25 mm (0.1634 to 0.1673 in.)
      35635-50241 43 4.25 to 4.35 mm (0.1674 to 0.1712 in.)
      35635-50201 44 4.35 to 4.45 mm (0.1713 to 0.1751 in.)
      35635-50251 45 4.45 to 4.55 mm (0.1752 to 0.1791 in.)
      35635-50211 46 4.55 to 4.65 mm (0.1792 to 0.1830 in.)
      35635-50261 47 4.65 to 4.75 mm (0.1831 to 0.1870 in.)
      35635-50221 48 4.75 to 4.85 mm (0.1871 to 0.1909 in.)
  25. INSPECT INDIVIDUAL PISTON OPERATION 
    1. Check the operating sound while applying compressed air into the oil holes indicated in the illustration.
      GTY670185Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      *1 Forward Clutch
      *2 Direct Clutch
      *3 Overdrive Clutch
      *4 Reverse Clutch
      *5 No. 1 Brake
      *6 No. 2 Brake (IN)
      *7 No. 2 Brake (OUT)
  26. INSPECT AUTOMATIC TRANSMISSION CASE SUB-ASSEMBLY 
    1. Using a caliper gauge, measure the inside diameter of the automatic transmission case sleeve bush.
      GTY545057Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Standard Inside Diameter

      51.470 to 51.555 mm (2.027 to 2.029 in.)

      If the inside diameter is not as specified, replace the automatic transmission case sub-assembly.

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