Automatic Transmission Unit (For 1Gd-Ftv) Inspection

Using a caliper gauge, measure the inside diameter of the direct clutch drum sub-assembly bushing.

Standard inside diameter:

59.515 to 59.540 mm (2.3432 to 2.3440 in.)

Using a caliper gauge, measure the inside diameter of the input shaft sub-assembly bushing.

Standard inside diameter:

20.000 to 20.025 mm (0.7874 to 0.7883 in.)

Using a caliper gauge, measure the inside diameter of the forward clutch hub sub-assembly bushing.

Standard inside diameter:

26.037 to 26.062 mm (1.0251 to 1.0260 in.)

Using a caliper gauge, measure the inside diameter of the sun gear input drum sub-assembly bushing.

Standard inside diameter:

35.811 to 35.835 mm (1.4099 to 1.4108 in.)

Using a caliper gauge, measure the inside diameter of the front planetary gear assembly bushing.

Standard inside diameter:

35.811 to 35.835 mm (1.4099 to 1.4108 in.)

Using a caliper gauge, measure the inside diameter of the front planetary ring gear flange sub-assembly bushing.

Standard inside diameter:

54.038 to 54.063 mm (2.1275 to 2.1284 in.)

Using a caliper gauge, measure the inside diameter of the rear planetary ring gear flange sub-assembly bushing.

Standard inside diameter:

32.176 to 32.201 mm (1.2668 to 1.2677 in.)

Using a feeler gauge, measure the center planetary gear pinion thrust clearance.

Standard clearance:

0.12 to 0.68 mm (0.00473 to 0.0267 in.)

Using a feeler gauge, measure the rear planetary gear pinion thrust clearance.

Standard clearance:

0.2 to 0.6 mm (0.00788 to 0.0236 in.)

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

Standard inside diameter:

20.000 to 20.025 mm (0.7874 to 0.7883 in.)

Hold the rear planetary ring gear and turn the No. 3 one-way clutch assembly.

Text in Illustration

	Lock
	Free

Check that the No. 3 one-way clutch assembly turns freely when turned counterclockwise and locks when turned clockwise.
If there is a problem with the No. 3 one-way clutch assembly, replace it.

Using a dial indicator, check the intermediate shaft runout.

Standard runout:

0.03 mm (0.00118 in.)

Using a micrometer, check the outer diameter of the intermediate shaft at each point shown in the illustration.

Standard diameter:

A:

32.062 to 32.075 mm (1.2623 to 1.2627 in.)

B:

25.962 to 25.975 mm (1.0222 to 1.0226 in.)

C:

19.963 to 19.976 mm (0.7860 to 0.7864 in.)

Using a vernier caliper, measure the free length of the forward clutch return spring sub-assembly including the spring seat.

Standard free length:

26.74 mm (1.053 in.)

Using a vernier caliper, measure the free length of the direct clutch return spring sub-assembly including the spring seat.

Standard free length:

22.14 mm (0.872 in.)

Using a vernier caliper, measure the free length of the No. 1 brake piston return spring sub-assembly including the spring seat.

Standard free length:

16.72 mm (0.658 in.)

Using a vernier caliper, measure the free length of the No. 2 brake piston return spring sub-assembly including the spring seat.

Standard free length:

16.68 mm (0.657 in.)

Using a vernier caliper, measure the free length of the 1st and reverse brake return spring sub-assembly including the spring seat.

Standard free length:

23.74 mm (0.935 in.)

Check if the contact surfaces of the No. 1 clutch discs, No. 1 clutch plates and No. 1 clutch flange are worn or burnt.
If necessary, replace them.

NOTICE:

1. If the lining of any No. 1 clutch disc is peeled or discolored, or even if part of a groove is damaged, replace all the No. 1 clutch discs.
   
2. Before installing new No. 1 clutch discs, soak them in ATF for at least 15 minutes.
   

Check if the contact surfaces of the No. 2 clutch discs, No. 2 clutch plates and No. 2 clutch flange are worn or burnt.
If necessary, replace them.

NOTICE:

1. If the lining of any No. 2 clutch disc is peeled or discolored, or even if part of a groove is damaged, replace all the No. 2 clutch discs.
   
2. Before installing new No. 2 clutch discs, soak them in ATF for at least 15 minutes.
   

Check if the contact surfaces of the No. 1 brake discs, No. 1 brake plates and No. 1 brake flange are worn or burnt.
If necessary, replace them.

NOTICE:

1. If the lining of any No. 1 brake disc is peeled or discolored, or even if part of a groove is damaged, replace all the No. 1 brake discs.
   
2. Before installing new No. 1 brake discs, soak them in ATF for at least 15 minutes.
   

Check if the contact surfaces of the No. 2 brake discs, No. 2 brake plates and No. 2 brake flanges are worn or burnt.
If necessary, replace them.

NOTICE:

1. If the lining of any No. 2 brake disc is peeled or discolored, or even if part of a groove is damaged, replace all the No. 2 brake discs.
   
2. Before installing new No. 2 brake discs, soak them in ATF for at least 15 minutes.
   

Check if the contact surfaces of the No. 4 brake discs, No. 4 brake plates and No. 4 brake flanges are worn or burnt.
If necessary, replace them.

NOTICE:

1. If the lining of any No. 4 brake disc is peeled or discolored, or even if part of a groove is damaged, replace all the No. 4 brake discs.
   
2. Before installing new No. 4 brake discs, soak them in ATF for at least 15 minutes.
   

Using a dial indicator, measure the clearance of the No. 1 clutch at several points while applying compressed air (196 kPa, 2.0 kgf/cm², 28 psi) to the oil hole as shown in the illustration, and calculate the average.

Standard clearance:

0.75 to 1.05 mm (0.0296 to 0.0413 in.)

HINT:

There are forward clutch flanges of different thicknesses.

Forward Clutch Flange Thickness:

Part No.	Thickness (mm (in.))
35635-71010	3.0 (0.118)
35635-71020	3.1 (0.122)
35635-71030	3.2 (0.126)
35635-71040	3.3 (0.130)
35635-71050	3.4 (0.134)
35635-71060	3.5 (0.138)
35635-71070	3.6 (0.142)
35635-71080	3.7 (0.146)
35635-71090	3.8 (0.150)
35635-71100	3.9 (0.154)
35635-71110	4.0 (0.157)
35635-71120	4.1 (0.161)
35635-71130	4.2 (0.165)

Using a dial indicator, measure the clearance of the No. 2 clutch at several points while applying compressed air (196 kPa, 2.0 kgf/cm², 28 psi) to the oil hole as shown in the illustration, and calculate the average.

Standard clearance:

0.5 to 0.8 mm (0.0197 to 0.0314 in.)

HINT:

There are direct clutch flanges of different thicknesses.

Direct Clutch Flange Thickness:

Part No.	Thickness (mm (in.))
35675-71010	3.0 (0.118)
35675-71020	3.1 (0.122)
35675-71030	3.2 (0.126)
35675-71040	3.3 (0.130)
35675-71050	3.4 (0.134)
35675-71060	3.5 (0.138)
35675-71070	3.6 (0.142)
35675-71080	3.7 (0.146)
35675-71090	3.8 (0.150)

Make sure that the No. 1 brake piston moves smoothly when applying and releasing compressed air (392 kPa, 4.0 kgf/cm², 57 psi).

Using a feeler gauge, measure the No. 1 brake pack clearance between the No. 1 brake disc and No. 1 brake flange.

Standard clearance:

0.4 to 0.7 mm (0.0158 to 0.0275 in.)

No. 1 Brake Flange Thickness:

Mark	Thickness (mm (in.))
0	4.9 (0.193)
1	5.0 (0.197)
2	5.1 (0.201)
3	5.2 (0.205)
4	5.3 (0.209)
5	5.4 (0.213)
6	5.5 (0.217)
7	5.6 (0.220)
8	5.7 (0.224)
A	5.8 (0.228)

Make sure that the No. 2 brake piston moves smoothly when applying and releasing compressed air (392 kPa, 4.0 kgf/cm², 57 psi).

Using a feeler gauge, measure the No. 2 brake pack clearance between the No. 2 brake disc and No. 2 brake flange.

Standard clearance:

0.5 to 0.8 mm (0.0197 to 0.0314 in.)

No. 2 Brake Flange Thickness:

Mark	Thickness (mm (in.))
0	2.0 (0.0787)
1	2.1 (0.0827)
2	2.2 (0.0866)
3	2.3 (0.0906)
4	2.4 (0.0945)
5	2.5 (0.0984)
6	2.6 (0.102)
7	2.7 (0.106)
8	2.8 (0.110)

Make sure that the 1st and reverse brake piston moves smoothly when applying and releasing compressed air (392 kPa, 4.0 kgf/cm², 57 psi).

Using a feeler gauge, measure the No. 4 brake pack clearance between the No. 4 brake disc and No. 4 brake flange.

Standard clearance:

0.7 to 1.0 mm (0.0276 to 0.0393 in.)

No. 4 Brake Flange Thickness:

Mark	Thickness (mm (in.))
0	1.80 (0.0709)
1	1.97 (0.0776)
3	2.11 (0.0831)
4	2.25 (0.0886)
5	2.39 (0.0941)
7	2.53 (0.0996)
8	2.67 (0.105)
10	2.81 (0.111)
11	2.95 (0.116)
12	3.09 (0.122)
14	3.23 (0.127)