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Automatic Transmission Unit: Inspection

  1. INSPECT AUTOMATIC TRANSMISSION OIL PAN SUB-ASSEMBLY 
    1. Remove the magnets, and use them to collect steel particles.
      2. Fig 1: Identifying Collect Steel Particles
      G04963559Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. 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 
    1. Hold the reverse clutch hub and turn the No. 2 1-way clutch assembly.
    2. Check that the No. 2 1-way clutch assembly turns freely clockwise and locks when turned counterclockwise.
      Fig 2: Identifying No. 2 1 -Way Clutch Assembly
      G04963560Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  3. INSPECT NO. 3 BRAKE DISC 
    1. 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 slight damage.
      NOTE: Before assembling new discs, soak them in ATF for at least 15 minutes.
      Fig 3: Identifying No. 3 Brake Disc
      G04963561Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  4. INSPECT NO. 3 BRAKE PISTON RETURN SPRING SUB-ASSEMBLY 
    1. Using vernier calipers, measure the free length of the spring together with the spring seat.

      Standard free length: 

      15.72 mm (0.619 in.) 

      Fig 4: Identifying Free Length Of Spring
      G04963562Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  5. INSPECT FRONT PLANETARY GEAR ASSEMBLY 
    1. Using a feeler gauge, measure the front planetary pinion gear thrust clearance.

      Standard clearance: 

      0.2 to 0.60 mm (0.008 to 0.024 in.) 

      Maximum clearance: 

      0.65 mm (0.026 in.) 

      If the clearance is greater than the maximum, replace the front planetary gear assembly.

      Fig 5: Identifying Front Planetary Pinion Gear Thrust Clearance
      G04963563Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using a dial indicator, measure the inside diameter of the front planetary gear bushing.

      Maximum inside diameter: 

      57.48 mm (2.263 in.) 

      If the inside diameter is greater than the maximum, replace the front planetary gear.

      Fig 6: Identifying Inside Diameter Of Front Planetary Gear Bushing
      G04963564Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  6. INSPECT 1 -WAY CLUTCH ASSEMBLY 
    1. Install the 1-way clutch assembly onto the 1-way clutch inner race.
      2. Fig 7: Identifying 1 -Way Clutch Assembly
      G04963565Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Hold the 1-way clutch inner race and turn the 1-way clutch assembly.
    3. Check that the 1-way clutch assembly turns freely counterclockwise and locks when turned clockwise.
    4. Remove the 1-way clutch assembly from the 1-way clutch inner race.
  7. INSPECT NO. 1 BRAKE DISC 
    1. 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 slight damage.
      NOTE: Before assembling new discs, soak them in ATF for at least 15 minutes.
      Fig 8: Identifying No. 1 Brake Disc
      G04963561Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  8. INSPECT BRAKE PISTON RETURN SPRING SUB-ASSEMBLY 
    1. Using vernier calipers, measure the free length of the spring together with the spring seat.

      Standard free length: 

      17.05 mm (0.671 in.) 

      Fig 9: Identifying Free Length Of Spring
      G04963567Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  9. INSPECT NO. 2 BRAKE DISC 
    1. 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 slight damage.
      NOTE: Before assembling new discs, soak them in ATF for at least 15 minutes.
      Fig 10: Identifying No. 2 Brake Disc
      G04963561Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  10. INSPECT NO. 2 BRAKE PISTON RETURN SPRING SUB-ASSEMBLY 
    1. Using vernier calipers, measure the free length of the spring together with the spring seat.

      Standard free length: 

      17.45 mm (0.687 in.) 

      Fig 11: Identifying Free Length Of Spring
      G04963569Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  11. INSPECT CENTER PLANETARY GEAR ASSEMBLY 
    1. Using a feeler gauge, measure the center planetary gear pinion thrust clearance.

      Standard clearance: 

      0.12 to 0.68 mm (0.005 to 0.027 in.) 

      Maximum clearance: 

      0.73 mm (0.029 in.) 

      If the clearance is greater than the maximum, replace the center planetary gear assembly.

      Fig 12: Identifying Center Planetary Gear Pinion Thrust Clearance
      G04963570Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  12. INSPECT NO. 3 1-WAY CLUTCH ASSEMBLY 
    1. Hold the rear planetary ring gear flange sub assembly and turn the 1-way clutch assembly.
      2. Fig 13: Identifying No. 3 1-Way Clutch Assembly
      G04963571Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Check that the 1-way clutch assembly turns freely counterclockwise and locks when turned clockwise.
  13. INSPECT REAR PLANETARY RING GEAR FLANGE SUB-ASSEMBLY 
    1. Using a dial indicator, measure the inside diameter of the rear planetary ring gear bushing.

      Maximum inside diameter: 

      32.18 mm (1.2667 in.) 

      If the inside diameter is greater than the maximum, replace the rear planetary ring gear.

      Fig 14: Identifying Inside Diameter Of Rear Planetary Ring Gear Bushing
      G04963572Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  14. INSPECT INTERMEDIATE SHAFT 
    1. Using a dial indicator, check the intermediate shaft runout.

      Maximum runout: 

      0.08 mm (0.003 in.) 

      NOTE: If the bend exceeds the specification, replace the intermediate shaft with a new one.
      Fig 15: Identifying Intermediate Shaft Runout
      G04963573Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. 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 (1.022 to 1.023 in.) 

      B: 

      25.962 to 25.975 mm (1.022 to 1.023 in.) 

      C: 

      32.062 to 32.075 mm (1.262 to 1.263 in.) 

      D: 

      32.062 to 32.075 mm (1.262 to 1.263 in.) 

      Minimum diameter: 

      A: 

      25.912 mm (1.020 in.) 

      B: 

      25.912 mm (1.020 in.) 

      C: 

      32.012 mm (1.260 in.) 

      D: 

      32.012 mm (1.260 in.) 

      NOTE: If the outer diameter is outside the standard, replace the intermediate shaft with a new one.
      Fig 16: Identifying Outer Diameter Of Intermediate Shaft
      G04963574Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  15. INSPECT NO. 4 BRAKE DISC 
    1. 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 slight damage.
      NOTE: Before assembling new discs, soak them in ATF for at least 15 minutes.
      Fig 17: Identifying No. 4 Brake Disc
      G04963561Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  16. INSPECT REAR PLANETARY GEAR ASSEMBLY 
    1. 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 in.) 

      Maximum clearance: 

      0.65 mm (0.026 in.) 

      If the clearance is greater than the maximum, replace the planetary gear assembly.

      Fig 18: Identifying Rear Planetary Gear Pinion Thrust Clearance
      G04963576Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using a dial indicator, measure the inside diameter of the rear planetary gear bushing.

      Maximum inside diameter: 

      20.075 mm (0.7904 in.) 

      If the inside diameter is greater than the maximum, replace the rear planetary gear assembly.

      Fig 19: Identifying Inside Diameter Of Rear Planetary Gear Bushing
      G04963577Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  17. INSPECT 1ST AND REVERSE BRAKE RETURN SPRING SUB-ASSEMBLY 
    1. Using vernier calipers, measure the free length of the spring together with the spring seat.

      Standard free length: 

      23.74 mm (0.9347 in.) 

      Fig 20: Identifying Free Length Of Spring
      G04963578Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  18. INSPECT PACK CLEARANCE OF FIRST AND REVERSE BRAKE 
    1. Make sure the 1st and reverse brake pistons move smoothly when applying and releasing the compressed air into the transmission case.
      Fig 21: Identifying Compressed Air Into Transmission Case
      G04963579Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  19. INSPECT NO. 1 PISTON STROKE OF BRAKE PISTON 
    1. Make sure the No. 1 brake piston moves smoothly when applying and releasing the compressed air into the transmission case.
      Fig 22: Identifying Compressed Air Into Transmission Case
      G04963580Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  20. INSPECT INDIVIDUAL PISTON OPERATION INSPECTION 
    1. Check the operating sound while applying compressed air into the oil holes indicated in the illustration.

      HINT:

      When inspecting the O/D direct clutch, use the C3 accumulator piston holes indicated in the illustration. If there is no sound, disassemble 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 (B3)
      5. No. 1 brake (B1)
      6. No. 2 brake (B2)
      7. No. 4 brake (B4)
        Fig 23: Identifying Oil Holes
        G04963582Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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