Toyota 4Runner manuals

Toyota 4Runner: Inspection

INSPECTION

PROCEDURE

1. INSPECT AUTOMATIC TRANSMISSION OIL PAN SUB-ASSEMBLY

(a) Remove the magnets and use them to collect steel particles.

(b) 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): bush wear

2. INSPECT NO. 2 1-WAY CLUTCH ASSEMBLY


(a) Hold the reverse clutch hub and turn the 1-way clutch assembly.

(b) Check that the 1-way clutch turns freely when turned clockwise and locks when turned counterclockwise.

Text in Illustration

Lock

Free

3. INSPECT REAR CLUTCH DISC


(a) Replace all the 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) the grooves or printed numbers have even a little bit of damage.

NOTICE:

When assembling new discs, soak them in ATF for at least 15 minutes before assembly.

4. INSPECT REVERSE CLUTCH HUB SUB-ASSEMBLY


(a) Using a dial indicator, measure the inside diameter of the reverse clutch hub bush.

Standard inside diameter:

35.812 to 35.837 mm (1.410 to 1.411 in.)

Maximum inside diameter:

35.887 mm (1.413 in.)

  • If the inside diameter is more than the maximum, replace the reverse clutch hub.

5. INSPECT FORWARD CLUTCH HUB SUB-ASSEMBLY


(a) Using a dial indicator, measure the inside diameter of the forward clutch hub bush.

Standard inside diameter:

26.037 to 26.062 mm (1.025 to 1.026 in.)

Maximum inside diameter:

26.112 mm (1.028 in.)

  • If the inside diameter is more than the maximum, replace the forward clutch hub.

6. INSPECT FORWARD MULTIPLE DISC CLUTCH DISC


(a) Replace all the 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) the grooves or printed numbers have even a little bit of damage.

NOTICE:

When assembling new discs, soak them in ATF for at least 15 minutes before assembly.

7. INSPECT FORWARD CLUTCH RETURN SPRING SUB-ASSEMBLY


(a) Using a vernier caliper, measure the free length of the spring together with the spring seat.

Standard free length:

26.74 mm (1.05 in.)

8. INSPECT DIRECT CLUTCH DISC


(a) Replace all the 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) the grooves or printed numbers have even a little bit of damage.

NOTICE:

When assembling new discs, soak them in ATF for at least 15 minutes before assembly.

9. INSPECT REVERSE CLUTCH RETURN SPRING SUB-ASSEMBLY


(a) Using a vernier caliper, measure the free length of the spring together with the spring seat.

Standard free length:

21.04 mm (0.828 in.)

10. INSPECT DIRECT CLUTCH RETURN SPRING SUB-ASSEMBLY


(a) Using a vernier caliper, measure the free length of the spring together with the spring seat.

Standard free length:

19.51 mm (0.768 in.)

11. INSPECT NO. 3 BRAKE DISC


(a) Replace all the 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) the grooves or printed numbers have even a little bit of damage.

NOTICE:

When assembling new discs, soak them in ATF for at least 15 minutes before assembly.

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


(a) Using a vernier caliper, measure the free length of the spring together with the spring seat.

Standard free length:

15.72 mm (0.619 in.)

13. INSPECT FRONT PLANETARY GEAR ASSEMBLY


(a) Using a feeler gauge, measure the front planetary pinion gear thrust clearance.

Standard clearance:

0.2 to 0.6 mm (0.00787 to 0.0236 in.)

Maximum clearance:

0.65 mm (0.0256 in.)

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

(b) Using a cylinder gauge, measure the inside diameter of the front planetary gear bush.

Maximum inside diameter:

57.48 mm (2.26 in.)

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

14. INSPECT 1-WAY CLUTCH ASSEMBLY


(a) Install the 1-way clutch to the 1-way clutch inner race.

Text in Illustration

Lock

Free

(b) Hold the 1-way clutch inner race and turn the 1-way clutch assembly. Check that the 1-way clutch turns freely when turned counterclockwise and locks when turned clockwise.

(c) Remove the 1-way clutch from the 1-way clutch inner race.

15. INSPECT NO. 1 BRAKE DISC


(a) Replace all the 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) the grooves or printed numbers have even a little bit of damage.

NOTICE:

When assembling new discs, soak them in ATF for at least 15 minutes before assembly.

16. INSPECT BRAKE PISTON RETURN SPRING SUB-ASSEMBLY


(a) Using a vernier caliper, measure the free length of the spring together with the spring seat.

Standard free length:

17.05 mm (0.671 in.)

17. INSPECT NO. 2 BRAKE DISC


(a) Replace all the 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) the grooves or printed numbers have even a little bit of damage.

NOTICE:

When assembling new discs, soak them in ATF for at least 15 minutes before assembly.

18. INSPECT NO. 2 BRAKE PISTON RETURN SPRING SUB-ASSEMBLY


(a) Using a vernier caliper, measure the free length of the spring together with the spring seat.

Standard free length:

17.45 mm (0.687 in.)

19. INSPECT CENTER PLANETARY GEAR ASSEMBLY


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

Standard clearance:

0.12 to 0.68 mm (0.00472 to 0.0268 in.)

Maximum clearance:

0.73 mm (0.0287 in.)

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

20. INSPECT NO. 3 1-WAY CLUTCH ASSEMBLY


(a) Hold the rear planetary ring gear flange and turn the 1-way clutch. Check that the 1-way clutch turns freely when turned counterclockwise and locks when turned clockwise.

Text in Illustration

Lock

Free

21. INSPECT REAR PLANETARY RING GEAR FLANGE SUB-ASSEMBLY


(a) Using a dial indicator, measure the inside diameter of the rear planetary ring gear bush.

Standard inside diameter:

32.176 to 32.201 (1.267 to 1.268 in.)

Maximum inside diameter:

32.251 mm (1.270 in.)

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

22. INSPECT INTERMEDIATE SHAFT


(a) Using a dial indicator, measure the intermediate shaft runout.

Standard runout:

0.03 mm (0.00118 in.)

Maximum runout:

0.08 mm (0.00315 in.)

If the runout is more than the maximum, replace the intermediate shaft with a new one.

(b) Using a micrometer, measure the diameter of the intermediate shaft at the positions shown in the diagram.

Standard diameter:

A, B

25.962 to 25.975 mm (1.022 to 1.023 in.)

C, D

32.062 to 32.075 mm (1.262 to 1.263 in.)

Minimum diameter:

A, B

25.912 mm (1.02 in.)

C, D

32.012 mm (1.26 in.)

If the diameter is less than the minimum, replace the intermediate shaft with a new one.


23. INSPECT NO. 4 BRAKE DISC


(a) Replace all the 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) the grooves or printed numbers have even a little bit of damage.

NOTICE:

When assembling new discs, soak them in ATF for at least 15 minutes before assembly.

24. INSPECT REAR PLANETARY GEAR ASSEMBLY


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

Standard clearance:

0.2 to 0.6 mm (0.00787 to 0.0236 in.)

Maximum clearance:

0.65 mm (0.0256 in.)

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

(b) Using a dial indicator, measure the inside diameter of the rear planetary gear bush.

Maximum inside diameter:

20.075 mm (0.790 in.)

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

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


(a) Using a vernier caliper, measure the free length of the spring together with the spring seat.

Standard free length:

23.74 mm (0.935 in.)

26. INSPECT 1ST AND REVERSE BRAKE


(a) Make sure the 1st and reverse brake piston moves smoothly when applying compressed air into and releasing compressed air from the transmission case.

27. INSPECT NO. 1 BRAKE


(a) Make sure the No. 1 brake piston moves smoothly when applying compressed air into and releasing compressed air from the transmission case.

28. INSPECT INDIVIDUAL PISTON OPERATION

(a) Check the operating sound while applying compressed air into the oil holes indicated in the illustration.

HINT:

When inspecting the O/D direct clutch, check with the C3 accumulator piston hole closed.

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)

Disassembly
DISASSEMBLY PROCEDURE 1. REMOVE TRANSMISSION CONTROL SHAFT LEVER LH (a) Remove the nut, spring washer and control shaft lever LH. 2. REMOVE PARK/NEUTRAL POSITION SWITCH ASSEMBLY (a) Using a s ...

Reassembly
REASSEMBLY PROCEDURE 1. BEARING POSITION Bearing and Race Diameter: Mark Front Race Diameter Inside/Outside Thrust Bearing Diameter Inside/Outside Re ...

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