Part 4

Transmission Disassemble

Inspection Procedure




1. Using a dial indicator, measure the input shaft end play.

Standard end play - 0.262 to 1.249 mm (0.0103 to 0.0492 in)




2. Inspect pack clearance of forward clutch.
3. Install the forward clutch on the oil pump.
4. Using a dial indicator, measure the forward clutch piston stroke while applying and releasing compressed air (1).

Standard position stroke - 1.74 to 2.08 mm (0.0685 to 0.0819 in)

5. If the piston stroke is less than the minimum, the parts may have been assembled incorrectly. Check and reassemble again.

Note: As the opening is big, cover it with a shop rag to prevent the compressed air from being discharged

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




7. Inspect the forward multiple disc clutch disc.

Note:
* If the lining of the disc is peeling off or discolored, replace all discs.
* Before assembling new discs, soak them in ATF WS for at least 15 minutes.

8. Check to see if the sliding surface of the disc, plate and flange are worn or burnt. If necessary, replace them.




9. Inspect the forward clutch return spring sub-assembly.
10. Using a vernier caliper, measure the free length of the spring together with the spring seat.

Standard free length - 28.23 mm (1.1102 in)




11. Inspect the forward clutch piston subassembly.
12. Shake the piston to check that the check ball is not stuck.
13. Check that air does not leak from the valve when applying low compressed air.




14. Inspect the multiple disc clutch hub.

Note:
* When the diameter is over the maximum, replace the multiple disc clutch hub with a new one.
* Check the contact surface of the bush in the direct clutch shaft. If any scratch or discolor is identified, replace the direct clutch subassembly with a new one.

15. Using a caliper gage, measure the inside diameter of the forward clutch hub bushing.

* Standard inside diameter - 23.025 to 23.045 mm (0.9065 to 0.9073 in.)
* Maximum inside diameter - 23.09 mm (0.9091 in.)

16. If the inside diameter is greater then the maximum, replace the forward clutch hub.




17. Inspect the underdrive clutch pack clearance.
18. Install the underdrive clutch to the transaxle.




19. Using a dial indicator, measure the underdrive clutch pack clearance while applying and releasing compressed air.

Standard pack clearance - 1.51 to 1.90 mm (0.0594 to 0.0748 in)

20. If the pack clearance is not as specified, inspect the discs, plates and flange.




21. Inspect the No. 1 underdrive clutch disc.

Note:
* If the lining of the discs is peeling off or discolored, or even if a part of the printed mark is defaced, replace all discs.
* Before assembling new discs, soak them in ATF WS for at least 15 minutes.

22. Check to see if the sliding surface of the disc, plate and flange are worn or burnt. If necessary, replace them.




23. Inspect the underdrive clutch drum subassembly.

* Standard drum bush - 37.06 to 37.08 mm (1.4591 to 1.4598 in.)
* Maximum drum bush - 37.13 mm (1.4618 in.)

If the inside diameter is greater then the maximum, replace the underdrive clutch drum sub-assembly.




24. Inspect underdrive clutch return spring sub-assembly.
25. Using a vernier caliper, measure the free length of the spring together with the spring seat.

Standard free length - 17.14 mm (0.6752 in.)




26. Inspect the No. 2 underdrive clutch disc.

Notice:
* If the lining of the disc is peeling off or discolored, or even if a part of the groove is defaced, replace all discs.
* Before assembling new discs, soak them in ATF WS for at least 15 minutes.

27. Check to see if the sliding surface of the disc, plate and flange are worn or burnt. If necessary, replace them.




28. Inspect the underdrive brake return spring sub-assembly.
29. Using a vernier caliper, measure the free length of the spring together with the spring seat.

Standard free length - 14.04 mm (0.5528 in)




30. Inspect the pack clearance of direct clutch.
31. Install the direct clutch and needle roller bearing on the transaxle rear cover.
32. Using a dial indicator, measure the forward clutch pack clearance while applying and releasing compressed air.

Standard pack clearance - 0.515 to 0.825 mm (0.0203 to 0.0324 in.)
If the pack clearance is not as specified, inspect the discs, plates and flange.




33. Inspect the direct multiple disc clutch disc.

Note:
* If the lining of the disc is peeling off or discolored, or even if a part of the printed mark is defaced, replace all discs.
* Before assembling new discs, soak them in ATF WS for at least 15 minutes.

34. Check to see if the sliding surface of the disc, plate and flange are worn or burnt. If necessary, replace them.




35. Inspect the direct clutch return spring sub-assembly.
36. Using a vernier caliper, measure the free length of the spring together with the spring seat.

Standard free length - 22.58 mm (0.8898 in)




37. Inspect the 2nd brake clutch disc.

Note:
* If the lining of the disc is peeling off or discolored, or even if a part of the printed mark is defaced, replace all discs.
* Before assembling new discs, soak them in ATF WS for at least 15 minutes.

38. Check to see if the sliding surface of the disc, plate and flange are worn or burnt. If necessary, replace them.




39. Inspect the 2nd brake piston return spring sub-assembly.
40. 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)




41. Inspect the 1st and reverse brake clutch disc.

Note:
* If the lining of the disc is peeling off or discolored, or even if a part of the printed mark is defaced, replace all discs.
* Before assembling new discs, soak them in ATF WS for at least 15 minutes.

42. Check to see if the sliding surface of the disc, plate and flange are worn or burnt. If necessary, replace them.




43. Inspect the 1st and reverse brake return spring sub-assembly.
44. Using a vernier caliper, measure the free length of the spring together with the spring seat.

Standard free length - 15.5 mm (0.6106 in)




45. Inspect the underdrive 1-way clutch assembly.
46. Install the underdrive clutch assembly to the 1-way clutch. Rotate the underdrive clutch assembly to check the rotating direction for the lock or free operation.