LEMON Manuals: Even more car manuals for everyone
Home >> Toyota >> 2009 >> Matrix Base, Standard >> Repair and Diagnosis >> External Pages >> Different variant/trim >> Section 13 (Automatic Transmission - U250E) >> Automatic Transaxle Unit >> Inspection

Automatic Transaxle Unit: Inspection

WARNING: This page is about a different variant/trim than selected.
  1. INSPECT TRANSMISSION OIL CLEANER MAGNET 
    1. Remove the magnets and use them to collect any steel chips. Examine the chips and particles in the pan and on the magnet to determine what type of wear has occurred in the transaxle.

      Result: 

      Steel (magnetic): bearing, gear, and plate wear 

      Brass (non-magnetic): bushing wear 

      Fig 1: Inspecting Transmission Oil Cleaner Magnet
      G04976097Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  2. INSPECT MULTIPLE DISC CLUTCH HUB 
    1. Using a caliper gauge, measure the inside diameter of the multiple disc clutch hub bushing.

      Standard inside diameter: 23.025 to 23.046 mm (0.9065 to 0.9073 in.) 

      Maximum inside diameter: 23.09 mm (0.9091 in.) 

      If the inside diameter is greater than the maximum, replace the multiple disc clutch hub with a new one.

      Fig 2: Measuring Inside Diameter Of Multiple Disc Clutch Hub Bushing
      G04976202Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE: Check the contact surface of the multiple disc clutch hub bushing. If any scratches or discoloration is found, replace the multiple disc clutch hub with a new one.
  3. INSPECT NO. 2 UNDERDRIVE CLUTCH DISC 
    1. Check if the contact surfaces of the discs, plates and flange are worn or burnt. If necessary, replace them.
      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.
        Fig 3: Identifying No. 2 Underdrive Clutch Disc
        G04976203Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  4. INSPECT OVERDRIVE DIRECT CLUTCH DRUM SUB-ASSEMBLY 
    1. Using a caliper gauge, measure the inside diameter of the overdrive direct clutch drum sub-assembly bushing.

      Standard inside diameter: 23.025 to 23.046 mm (0.9065 to 0.9073 in.) 

      Maximum inside diameter: 23.09 mm (0.9091 in.) 

      If the inside diameter is greater than the maximum, replace the overdrive direct clutch drum sub-assembly.

      Fig 4: Measuring Inside Diameter Of Overdrive Direct Clutch Drum Sub-Assembly Bushing
      G06011754Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE: Check the contact surface of the overdrive direct clutch drum bushing. If any scratches or discoloration is found, replace the overdrive direct clutch drum sub-assembly with a new one.
  5. INSPECT 2ND BRAKE DISC 
    1. Check if the contact surfaces of the discs, plates and flange are worn or burnt. If necessary, replace them.
      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.
        Fig 5: Identifying 2nd Brake Disc
        G04976205Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  6. INSPECT 1ST AND REVERSE BRAKE DISC 
    1. Check if the contact surfaces of the discs, plates and flange are worn or burnt.

      If necessary, replace them.

      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.
        Fig 6: Identifying 1st And Reverse Brake Disc
        G04976206Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  7. INSPECT 1ST AND REVERSE BRAKE RETURN SPRING SUB-ASSEMBLY 
    1. Using a vernier caliper, measure the free length of the spring together with the spring seat.

      Standard free length: 17.63 mm (0.6941 in.) 

      If the free length is shorter than the standard free length, replace the 1st and reverse brake return spring sub-assembly.

      Fig 7: Measuring Free Length Of Spring Together With Spring Seat
      G06011757Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  8. INSPECT UNDERDRIVE BRAKE RETURN SPRING SUB-ASSEMBLY 
    1. Using a vernier caliper, measure the free length of the spring together with the spring seat.

      Standard free length: 13.24 mm (0.5213 in.) 

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

      Fig 8: Measuring Free Length Of Spring Together With Spring Seat
      G04976207Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  9. INSPECT PACK CLEARANCE OF 1ST AND REVERSE BRAKE 
    1. Using a vernier caliper, measure the distance between the disc surface and the contact surface of the 2nd brake cylinder and transaxle case (Dimension A).
      Fig 9: Measuring Distance Between Disc Surface And Contact Surface Of 2nd Brake Cylinder
      G04976209Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Select an appropriate flange from the table below so that the pack clearance will be within the specified range.

      Pack clearance: 0.745 to 1.21 mm (0.0293 to 0.0476 in.) 

      HINT:

      Pack clearance = Dimension A - Flange thickness

      Flange Thickness 

      FLANGE THICKNESS SPECIFICATION

      Mark Thickness (mm (in.)) Mark Thickness (mm (in.))
      1 1.8 (0.0708) 5 2.2 (0.0866)
      2 1.9 (0.0748) 6 2.3 (0.0906)
      3 2.0 (0.0787) 7 2.4 (0.0945)
      4 2.1 (0.0827) 8 2.5 (0.0984)
    3. Install the flange.
  10. INSPECT PACK CLEARANCE OF 2ND BRAKE 
    1. Using a vernier caliper, measure the distance between the disc surface and snap ring surface (Dimension B).
      Fig 10: Measuring Distance Between Disc Surface And Snap Ring Surface
      G04976210Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Select an appropriate flange from the table below so that the pack clearance will be within the specified range.

      Pack clearance: 0.53 to 0.91 mm (0.0209 to 0.0358 in.) 

      HINT:

      Pack clearance = Dimension B - Flange thickness - Snap ring thickness 1.6 mm (0.0630 in.)

      Flange Thickness 

      FLANGE THICKNESS SPECIFICATION

      Mark Thickness (mm (in.)) Mark Thickness (mm (in.))
      0 2.9 (0.114) 5 3.4 (0.134)
      1 3.0 (0.118) 6 3.5 (0.138)
      2 3.1 (0.122) 7 3.6 (0.142)
      3 3.2 (0.126) 8 3.7 (0.146)
      4 3.3 (0.130) - -
    3. Install the flange.
  11. INSPECT PACK CLEARANCE OF UNDERDRIVE BRAKE 
    1. Using a dial indicator, measure the underdrive brake pack clearance while applying and releasing compressed air (392 kPa, 4.0 kgf/cm2 , 57 psi).

      Pack clearance: 1.81 to 2.20 mm (0.0713 to 0.0866 in.) 

      Fig 11: Inspecting Pack Clearance Of Underdrive Brake
      G04976211Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Select an appropriate flange from the table below so that the pack clearance will be within the specified range.

      Flange Thickness 

      FLANGE THICKNESS SPECIFICATION

      Mark Thickness (mm (in.)) Mark Thickness (mm (in.))
      Y 2.8 (0.110) C 3.4 (0.134)
      A 3.0 (0.118) D 3.6 (0.142)
      B 3.2 (0.126) - -
    3. Temporarily remove the snap ring and attach the flange to the transaxle case.
    4. Reinstall the snap ring to the transaxle case.
  12. INSPECT UNDERDRIVE ONE-WAY CLUTCH ASSEMBLY 
    1. Install the underdrive clutch assembly to the one-way clutch.
    2. Make sure that the underdrive one-way clutch turns freely counterclockwise and locks when turned clockwise.
      Fig 12: Checking Underdrive One-Way Clutch Turns Freely
      G04976212Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Remove the underdrive clutch assembly from the one-way clutch.
  13. INSPECT INPUT SHAFT END PLAY 
    1. Using a dial indicator, measure the input shaft end play.

      End play: 0.262 to 1.244 mm (0.0103 to 0.0490 in.) 

      Fig 13: Measuring Input Shaft End Play
      G04976213Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  14. INSPECT DIRECT MULTIPLE DISC CLUTCH DISC 
    1. Check if the contact surfaces of the discs, plates and flange are worn or burnt.

      If necessary, replace them.

      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.
        Fig 14: Identifying Direct Multiple Disc Clutch Disc
        G05559385Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  15. INSPECT OVERDRIVE DIRECT CLUTCH DISC 
    1. Check if the contact surfaces of the discs, plates and flange are worn or burnt.

      If necessary, replace them.

      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.
        • Fig 15: Identifying Overdrive Direct Clutch Disc
        G04976215Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  16. INSPECT OVERDRIVE CLUTCH RETURN SPRING SUB-ASSEMBLY 
    1. Using a vernier caliper, measure the free length of the spring together with the spring seat.

      Standard free length: 25.91 mm (1.0201 in.) 

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

      Fig 16: Measuring Free Length Of Spring Together With Spring Seat
      G05001024Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  17. INSPECT PACK CLEARANCE OF DIRECT CLUTCH 
    1. Install the intermediate shaft on the transaxle rear cover.
    2. Using a dial indicator, measure the direct clutch pack clearance while applying and releasing compressed air (392 kPa, 4.0 kgf/cm2 , 57 psi).

      Pack clearance: 1.05 to 1.47 mm (0.04134 to 0.05787 in.) 

      If the pack clearance is less than the minimum, the parts may have been assembled incorrectly. Check and reassemble them again.

      If the clearance is not as specified, select another flange.

      HINT:

      There are 8 different thicknesses of flanges available.

      Fig 17: Inspecting Pack Clearance Of Direct Clutch
      G04976217Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Flange Thickness 

      FLANGE THICKNESS SPECIFICATION

      Mark Thickness (mm (in.)) Mark Thickness (mm (in.))
      0 2.9 (0.114) 4 3.3 (0.130)
      1 3.0 (0.118) 5 3.4 (0.134)
      2 3.1 (0.122) 6 3.5 (0.138)
      3 3.2 (0.126) 7 3.6 (0.142)
  18. INSPECT PACK CLEARANCE OF OVERDRIVE CLUTCH 
    1. Using a dial indicator, measure the overdrive clutch pack clearance while applying and releasing compressed air (392 kPa, 4.0 kgf/cm2 , 57 psi).

      Pack clearance: 0.61 to 0.83 mm (0.02402 to 0.03268 in.) 

      If the pack clearance is less than the minimum, the parts may have been assembled incorrectly. Check and reassemble them again.

      If the clearance is not as specified, select another flange.

      HINT:

      There are 7 different thicknesses of flanges available.

      Fig 18: Inspecting Pack Clearance Of Overdrive Clutch
      G04976218Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Flange Thickness 

      FLANGE THICKNESS SPECIFICATION

      Mark Thickness (mm (in.)) Mark Thickness (mm (in.))
      0 2.5 (0.0984) 4 2.9 (0.114)
      1 2.6 (0.102) 5 3.0 (0.118)
      2 2.7 (0.106) 6 3.1 (0.122)
      3 2.8 (0.110) - -
    2. Check that the disc rotates after inserting the rear planetary sun gear.
      NOTE: Do not place the rear planetary sun gear in a vise.
      Fig 19: Checking Disc Rotates
      G04976221Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  19. INSPECT 2ND BRAKE PISTON RETURN SPRING SUB-ASSEMBLY 
    1. Using a vernier caliper, measure the free length of the spring together with the spring seat.

      Standard free length: 16.61 mm (0.6539 in.) 

      If the free length is shorter than the standard free length, replace the 2nd brake piston return spring sub-assembly.

      Fig 20: Measuring Free Length Of Spring Together With Spring Seat
      G06011772Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  20. INSPECT PACK CLEARANCE OF FORWARD CLUTCH 
    1. Install the forward clutch assembly to the oil pump.
      NOTE: Be careful not to damage the oil seal ring of the oil pump.
    2. Using a dial indicator, measure the forward clutch pack clearance while applying and releasing compressed air (392 kPa, 4.0 kgf/cm2 , 57 psi).

      Pack clearance: 1.00 to 1.25 mm (0.0394 to 0.0492 in.) 

      If the clearance is not within the standard, inspect the discs, plates and flange.

      HINT:

      • As the opening is large, cover it with a piece of cloth to prevent the compressed air from being released.
      • There are 7 different thicknesses of flanges available.
        Fig 21: Inspecting Pack Clearance Of Forward Clutch
        G05130210Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Flange Thickness 

      FLANGE THICKNESS SPECIFICATION

      Mark Thickness (mm (in.)) Mark Thickness (mm (in.))
      0 2.85 (0.1122) 4 3.45 (0.1358)
      1 3.00 (0.1181) 5 3.60 (0.1417)
      2 3.15 (0.1240) 6 3.75 (0.1476)
      3 3.30 (0.1299) - -
  21. INSPECT FORWARD MULTIPLE DISC CLUTCH DISC 
    1. Check if the contact surfaces of the discs, plates and flange are worn or burnt.

      If necessary, replace them.

      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.
        Fig 22: Identifying Forward Multiple Disc Clutch Disc
        G04976206Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  22. INSPECT FORWARD CLUTCH RETURN SPRING SUB-ASSEMBLY 
    1. Using a vernier caliper, measure the free length of the spring together with the spring seat.

      Standard free length: 26.74 mm (1.0528 in.) 

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

      Fig 23: Measuring Free Length Of Spring Together With Spring Seat
      G04976384Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  23. INSPECT FORWARD MULTIPLE DISC CLUTCH DISC 
    1. Check that the disc rotates when lightly rotating the forward clutch assembly after inserting the multiple disc clutch.
      NOTE: Do not place the forward clutch assembly in a vise.
      Fig 24: Checking Disc Rotation
      G04976385Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  24. INSPECT UNDERDRIVE PLANETARY GEAR PRELOAD 
    1. Using SST, secure the underdrive planetary gear assembly.

      SST 09387-00050,09495-65040 

      Fig 25: Identifying Underdrive Planetary Gear
      G04976403Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using SST and a torque wrench, measure the turning torque of the underdrive planetary gear assembly while turning the torque wrench at 60 rpm.

      SST 09387-00050, 09495-65040 

      Turning torque at 60 rpm: 0.28 to 0.89 N*m (2.9 to 9.1 kgf*cm, 2.5 to 7.9 in.*lbf) 

      HINT:

      Use a torque wrench with a fulcrum length of 160 mm (6.30 in.).

      Fig 26: Measuring Turning Torque Of Underdrive Planetary Gear Assembly
      G04976404Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  25. INSPECT PACK CLEARANCE OF UNDERDRIVE CLUTCH 
    1. Install the underdrive clutch to the transaxle case.
      NOTE: Be careful not to damage the oil seal rings.
    2. Install a dial indicator as shown in the illustration.
    3. Measure the underdrive clutch pack clearance while applying and releasing compressed air (392 kPa, 4.0 kgf/cm2 , 57 psi).

      Pack clearance: 1.51 to 1.71 mm (0.0594 to 0.0673 in.) 

      If the pack clearance is not within the specified range, inspect the discs, plates, and flange.

      Fig 27: Inspecting Pack Clearance Of Underdrive Clutch
      G04976426Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  26. INSPECT NO. 1 UNDERDRIVE CLUTCH DISC 
    1. Check if the contact surfaces of the discs, plates and flange are worn or burnt.

      If necessary, replace them.

      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.
        Fig 28: Identifying No. 1 Underdrive Clutch Disc
        G04976427Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  27. INSPECT UNDERDRIVE CLUTCH DRUM SUB-ASSEMBLY 
    1. Using a caliper gauge, measure the inside diameter of the underdrive clutch drum bushing.

      Standard inside diameter: 32.56 to 32.58 mm (1.2818 to 1.2826 in.) 

      Maximum inside diameter: 32.63 mm (1.2846 in.) 

      If the inside diameter is greater than the maximum, replace the underdrive clutch drum.

      Fig 29: Measuring Inside Diameter Of Underdrive Clutch Drum Bushing
      G04976428Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  28. INSPECT UNDERDRIVE CLUTCH RETURN SPRING SUB-ASSEMBLY 
    1. Using a vernier caliper, measure the free length of the spring together with the spring seat.

      Standard free length: 17.14 mm (0.6748 in.) 

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

      Fig 30: Measuring Free Length Of Spring Together With Spring Seat
      G06011782Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
scientia non olet · About LEMON Manuals