Transaxle Unit

U760E AUTOMATIC TRANSMISSION / TRANSAXLE: AUTOMATIC TRANSAXLE UNIT: INSPECTION

1. INSPECT TRANSMISSION OIL CLEANER MAGNET

(a) Examine the particles in the automatic transaxle oil pan.

(1) Collect any steel chips with the removed magnets. Look carefully at the chips and particles in the automatic transaxle oil pan and on the transmission oil cleaner magnets to see the type of wear which might be found in the automatic transaxle.

Result:

2. INSPECT INPUT SHAFT END PLAY

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

Standard end play:

0.020 to 1.242 mm (0.000788 to 0.0488 in.)

3. INSPECT INTERMEDIATE SHAFT END PLAY

(a) Clean the contact surfaces of the transaxle case and rear transaxle cover.

(b) As shown in the illustration, place a straightedge on the multiple direct clutch drum and measure the distance between the transaxle case and straightedge using a vernier caliper (dimension A).

Text in Illustration

Text in Illustration

(d) Calculate the end play value using the following formula:

End play = Dimension B - Dimension A - Thrust needle roller bearing thickness

Standard end play:

0.022 to 1.099 mm (0.000867 to 0.0432 in.)

4. INSPECT PLANETARY SUN GEAR SUB-ASSEMBLY

(a) Using a caliper gauge, measure the inside diameter of the bushings of the planetary sun gear.

Standard inside diameter:

25.525 to 25.546 mm (1.00492 to 1.00574 in.)

Maximum inside diameter:

25.546 mm (1.00574 in.)

If the inside diameter is more than the maximum, replace the planetary sun gear.

5. INSPECT REAR PLANETARY SUN GEAR ASSEMBLY

(a) Using a caliper gauge, measure the inside diameter of the bushing of the rear planetary sun gear.

Standard inside diameter:

25.580 to 25.601 mm (1.00709 to 1.00791 in.)

Maximum inside diameter:

25.601 mm (1.00791 in.)

If the inside diameter is more than the maximum, replace the rear planetary sun gear assembly

6. INSPECT UNDERDRIVE PLANETARY GEAR ASSEMBLY

(a) Using a feeler gauge, measure the clearance between the underdrive planetary gear assembly gear at 4 points.

Standard clearance:

0.18 to 0.54 mm (0.00709 to 0.0212 in.)

If the clearance is more than the standard clearance, replace the underdrive planetary gear assembly.

7. INSPECT ONE-WAY CLUTCH ASSEMBLY

(a) Temporarily install the one-way clutch assembly to the planetary ring gear.

Text in Illustration

(b) Make sure that the one-way clutch assembly turns freely counterclockwise and locks when turned clockwise.

If the one-way clutch assembly does not operate normally, replace it.

8. INSPECT NO. 1 BRAKE DISC

(a) Check if the contact surfaces of the No. 1 brake discs, No. 1 brake plates and No. 1 brake flange are worn or burnt.

NOTICE:
* 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.

If necessary, replace them.

9. INSPECT NO. 2 BRAKE DISC

(a) Check if the contact surfaces of the No. 2 brake discs, No. 2 brake plates and No. 2 brake flange are worn or burnt.

NOTICE:
* 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.

If necessary, replace them.

10. INSPECT NO. 3 BRAKE DISC

(a) Check if the contact surfaces of the No. 3 brake discs, No. 3 brake plates and No. 3 brake flanges are worn or burnt.

NOTICE:
* 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.

If necessary, replace them.

11. INSPECT 2ND BRAKE PISTON RETURN SPRING SUB-ASSEMBLY

(a) Using a vernier caliper, measure the free length of the 3 2nd brake piston return springs, including the spring seats.

Standard free length:

23.26 mm (0.916 in.)

If the free length is less than the standard free length, replace the 2nd brake piston return spring.

12. INSPECT 1ST AND REVERSE BRAKE RETURN SPRING SUB-ASSEMBLY

(a) Using a vernier caliper, measure the free length of the 1st and reverse brake return spring together with the spring seat.

Standard free length:

15.79 mm (0.622 in.)

If the free length is less than the standard free length, replace the 1st and reverse brake return spring.

13. INSPECT NO. 3 BRAKE PISTON RETURN SPRING SUB-ASSEMBLY

(a) Using a vernier caliper, measure the free length of the No. 3 brake piston return spring together with the spring seat.

Standard free length:

9.15 mm (0.360 in.)

If the free length is less than the standard free length, replace the No. 3 brake piston return spring.

14. INSPECT CLEARANCE OF NO. 1 BRAKE

(a) Using a dial indicator, measure the clearance of the No. 1 brake piston while applying compressed air (200 kPa, 2.0 kgf/cm2, 29 psi).

Standard clearance:

0.601 to 0.819 mm (0.0237 to 0.0322 in.)

HINT
Measure the clearance at 3 points where the No. 1 brake piston diameter is approximately 140 mm (5.51 in.) and calculate the average.

If the clearance is not as specified, select an appropriate No. 1 brake flange so that the clearance will be within the specified range.

No. 1 Brake Flange Thickness

15. INSPECT CLEARANCE OF NO. 2 BRAKE

(a) Using a dial indicator, measure the clearance of the No. 2 brake piston while applying compressed air (200 kPa, 2.0 kgf/cm2, 29 psi).

Standard clearance:

0.884 to 1.196 mm (0.0348 to 0.0470 in.)

HINT
Measure the clearance at 3 points where the No. 2 brake piston diameter is approximately 140 mm (5.51 in.) and calculate the average.

If the clearance is not as specified, select an appropriate No. 2 brake flange so that the clearance will be within the specified range.

No. 2 Brake Flange Thickness

16. INSPECT CLEARANCE OF NO. 3 BRAKE

(a) Using a vernier caliper and straightedge, measure the distance shown in the illustration (dimension A) while a load of 500 N (51 kgf, 112.4 lbf) is being applied to the flange.

Text in Illustration

HINT
Measure dimension A at 3 points where the No. 3 brake flange diameter is approximately 166 mm (6.54 in.) and calculate the average.

(b) Using a vernier caliper and straightedge, measure the distance shown in the illustration (dimension B).

HINT
Measure dimension B at 3 points where the No. 3 brake piston diameter is approximately 166 mm (6.54 in.) and calculate the average.

(c) Calculate the clearance value using the following formula:

Clearance = Dimension B - Dimension A - Flange Thickness

Standard clearance:

0.599 to 0.799 mm (0.0236 to 0.0315 in.)

If the clearance is not as specified, select an appropriate No. 3 brake flange so that the clearance will be within the specified range.

No. 3 Brake Flange Thickness

17. INSPECT CLEARANCE OF NO. 1 CLUTCH

(a) Install the rear multiple disc clutch assembly to the rear transaxle cover.

(b) Check that the piston moves when compressed air (200 kPa, 2.0 kgf/cm2, 29 psi) is applied to the oil hole.

(c) Using a feeler gauge, measure the No. 1 clutch pack clearance.

Text in Illustration

HINT
Measure the clearance at 3 points where the flange diameter is approximately 152 mm (5.98 in.) and calculate the average.

Standard pack clearance:

0.601 to 0.819 mm (0.0237 to 0.0322 in.)

If the pack clearance is not as specified, replace the rear multiple disc clutch assembly.

18. INSPECT CLEARANCE OF NO. 2 CLUTCH

(a) Install the rear multiple disc clutch assembly to the rear transaxle cover.

(b) Using a dial indicator, measure the No. 2 clutch pack clearance while applying and releasing compressed air (200 kPa, 2.0 kgf/cm2, 29 psi).

HINT
Measure the clearance at 3 points where the diameter of the No. 2 direct multiple clutch piston is approximately 152 mm (5.98 in.) and calculate the average.

Standard pack clearance:

0.394 to 0.605 mm (0.0156 to 0.0238 in.)

If the pack clearance is not as specified, replace the rear multiple disc clutch assembly.