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Home >> Toyota >> 2021 >> Highlander LE, 4WD >> Repair and Diagnosis >> Transmission >> Automatic Trans >> Automatic Transmission System (UA80F) - Service Information (2 Of 2) >> Automatic Transaxle Unit >> Inspection [12/2019 - 10/2022] >> Procedure

Inspection [12/2019 - 10/2022]: Procedure

  1. INSPECT TRANSMISSION OIL CLEANER MAGNET 
    1. Use the removed transmission oil cleaner magnets to collect any steel chips. Examine the chips and particles in the transaxle housing and on the transmission oil cleaner magnets to determine what type of wear might be found in the automatic transaxle assembly.
      GTY111851Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Result

      Steel (magnetic) 

      Bearing, gear and plate wear

      Brass (non-magnetic) 

      Bushing wear

  2. INSPECT FRONT CLUTCH DISC 
    1. Check if the contact surfaces of the front clutch disc, forward multiple disc clutch plate and forward clutch flange are worn or burnt.

      If necessary, replace them.

      GTY698846Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:
      • If the lining of any front clutch disc is peeled off or discolored, or even if part of the groove is damaged, replace all the front clutch discs.
      • Before assembling new front clutch discs, soak them in Toyota Genuine ATF WS for at least 15 minutes.
  3. INSPECT NO. 2 CLUTCH DISC 
    1. Check if the contact surfaces of the No. 2 clutch disc, No. 2 clutch plate and direct clutch flange are worn or burnt.
      GTY698845Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      If necessary, replace them.

      NOTE:
      • If the lining of any No. 2 clutch disc is peeled off or discolored, or even if part of the groove is damaged, replace all the No. 2 clutch discs.
      • Before assembling new No. 2 clutch discs, soak them in Toyota Genuine ATF WS for at least 15 minutes.
  4. INSPECT NO. 1 BRAKE DISC 
    1. Check if the contact surfaces of the No. 1 brake disc, No. 1 brake plate and No. 1 brake flange are worn or burnt.

      If necessary, replace them.

      GTY698837Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:
      • If the lining of any No. 1 brake disc is peeled off or discolored, or even if part of the groove is damaged, replace all the No. 1 brake discs.
      • Before assembling new No. 1 brake discs, soak them in Toyota Genuine ATF WS for at least 15 minutes.
  5. INSPECT 2ND BRAKE DISC 
    1. Check if the contact surfaces of the 2nd brake disc, 2nd brake plate and 2nd brake flange are worn or burnt.

      If necessary, replace them.

      GTY733626Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:
      • If the lining of any 2nd brake disc is peeled off or discolored, or even if part of the groove is damaged, replace all the 2nd brake discs.
      • Before assembling new 2nd brake discs, soak them in Toyota Genuine ATF WS for at least 15 minutes.
  6. INSPECT CLUTCH RETURN SPRING SUB-ASSEMBLY 
    1. Using a vernier caliper, measure the free length of the clutch return spring sub-assembly together with the spring seat.
      GTY698839Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Standard Free Length

      14.61 mm (0.575 in.)

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

  7. INSPECT 1ST AND REVERSE BRAKE RETURN SPRING SUB-ASSEMBLY 
    1. Using a vernier caliper, measure the free length of the 1st and reverse brake return spring sub-assembly together with the spring seat.
      GTY698808Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Standard Free Length

      18.29 mm (0.720 in.)

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

  8. INSPECT PLANETARY SUN GEAR SUB-ASSEMBLY 
    1. Using a caliper gauge, measure the inside diameter of the bushing of the planetary sun gear sub-assembly.
      GTY698810Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Standard Inside Diameter

      33.286 to 33.312 mm (1.310 to 1.311 in.)

      Maximum Inside Diameter

      33.312 mm (1.311 in.)

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

  9. INSPECT REAR PLANETARY SUN GEAR SUB-ASSEMBLY 
    1. Using a caliper gauge, measure the inside diameter of the bushing of the rear planetary sun gear sub-assembly.
      GTY698809Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Standard Inside Diameter

      24.287 to 24.313 mm (0.956 to 0.957 in.)

      Maximum Inside Diameter

      24.313 mm (0.957 in.)

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

  10. INSPECT FRONT PLANETARY GEAR ASSEMBLY 
    1. for Outer Pinion:
      GTY698812Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. Using a feeler gauge, measure the clearance between the planetary carrier and pinion gears at 5 points.

        Standard Clearance

        0.2 to 0.6 mm (0.00787 to 0.0236 in.)

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

    2. for Inner Pinion:
      GTY698811Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. Using a feeler gauge, measure the clearance between the planetary carrier and pinion gears at 5 points.

        Standard Clearance

        0.2 to 0.6 mm (0.00787 to 0.0236 in.)

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

  11. INSPECT REAR PLANETARY GEAR ASSEMBLY 
    1. for Long Pinion:
      GTY733618Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. Using a feeler gauge, measure the clearance between the planetary carrier and pinion gears at 4 points.

        Standard Clearance

        0.15 to 1.05 mm (0.00591 to 0.0413 in.)

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

    2. for Short Pinion:
      GTY698804Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. Using a feeler gauge, measure the clearance between the planetary carrier and pinion gears at 4 points.

        Standard Clearance

        0.15 to 0.85 mm (0.00591 to 0.0335 in.)

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

  12. INSPECT INPUT SHAFT END PLAY 
    1. Using a dial indicator, measure the input shaft end play.
      GTY733627Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Standard Input Shaft End Play

      0.332 to 1.103 mm (0.0131 to 0.0434 in.)

  13. INSPECT CLEARANCE OF C-3 CLUTCH 
    1. Set the C-3 and C-4 clutch assembly on the front oil pump assembly.
    2. Using a dial indicator, measure the clearance of the C-3 clutch while applying compressed air (approximately 200 kPa (2.0 kgf/cm 2 , 29 psi)).
      GTY724530Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Cover ATF Hole

      Pack Clearance (Reference)

      0.19 to 0.61 mm (0.00748 to 0.0240 in.)

      HINT: 

      • Cover the location shown in the illustration with your finger when applying compressed air.
      • To find the clearance, measure in at least 3 locations and average the results.

      If the clearance is not as specified, replace the C-3 and C-4 clutch assembly.

  14. INSPECT CLEARANCE OF C-4 CLUTCH 
    1. Set the C-3 and C-4 clutch assembly on the front oil pump assembly.
    2. Using a dial indicator, measure the clearance of the C-4 clutch while applying compressed air (approximately 400 kPa (4.1 kgf/cm 2 , 58 psi)).
      GTY731328Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Cover ATF Hole

      Pack Clearance (Reference)

      0.27 to 0.73 mm (0.0106 to 0.0287 in.)

      HINT: 

      • Cover the location shown in the illustration with your finger when applying compressed air.
      • To find the clearance, measure in at least 3 locations and average the results.

      If the clearance is not as specified, replace the C-3 and C-4 clutch assembly.

  15. INSPECT CLEARANCE OF C-1 CLUTCH 

    HINT: 

    GTY895120Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    Serial Number

    The component manufacturer (AW (AISIN AW) or TMMWV (TOYOTA)) can be determined based on the serial number as described in the following table.

    Serial Number Factory
    ##6######## AW (AISIN AW)
    ##A######## TMMWV (TOYOTA)
    1. Using a dial indicator, measure the clearance of the C-1 clutch while applying compressed air (approximately 200 kPa (2.0 kgf/cm 2 , 29 psi)).
      GTY698518Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Pack Clearance (Reference)

      1.0 to 1.2 mm (0.0394 to 0.0472 in.)

      HINT: 

      • Make sure to cover the ATF holes shown in the illustration.
      • To find the clearance, measure in at least 3 locations and average the results.

      If the clearance is not as specified, select an appropriate forward clutch flange so that the clearance will be within the specified range.

      Forward Clutch Flange Thickness

      FOR AW (AISIN AW) MADE:

      Part Number Thickness
      mm (in.)
      35635-48120 4.3 (0.169)
      35635-48130 4.4 (0.173)
      35635-48140 4.5 (0.177)
      35635-48150 4.6 (0.181)
      35635-48160 4.7 (0.185)
      35635-48170 4.8 (0.189)
      35635-48180 4.9 (0.193)
      35635-48190 5.0 (0.197)
      35635-48200 5.1 (0.201)
      FOR TMMWV MADE:

      Part Number Thickness
      mm (in.)      		 Mark
      35635-06130 4.3 (0.169) 0
      35635-06140 4.4 (0.173) 1
      35635-06150 4.5 (0.177) 2
      35635-06160 4.6 (0.181) 3
      35635-06170 4.7 (0.185) 4
      35635-06180 4.8 (0.189) 5
      35635-06190 4.9 (0.193) 6
      35635-06200 5.0 (0.197) 7
      35635-06210 5.1 (0.201) 8
  16. INSPECT CLEARANCE OF B-1 BRAKE 

    HINT: 

    GTY895120Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    Serial Number

    The component manufacturer (AW (AISIN AW) or TMMWV (TOYOTA)) can be determined based on the serial number as described in the following table.

    Serial Number Factory
    ##6######## AW (AISIN AW)
    ##A######## TMMWV (TOYOTA)
    1. Using a dial indicator, measure the clearance of the B-1 brake while applying compressed air (approximately 200 kPa (2.0 kgf/cm 2 , 29 psi)).
      GTY733548Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Pack Clearance

      0.8 to 1.0 mm (0.0315 to 0.0394 in.)

      HINT: 

      To find the clearance, measure in at least 3 locations and average the results.

      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

      FOR AW (AISIN AW) MADE:

      Part Number Thickness
      mm (in.)      		 Mark
      35676-48380 3.5 (0.138) 0
      35676-48390 3.6 (0.142) 1
      35676-48400 3.7 (0.146) 2
      35676-48410 3.8 (0.150) 3
      35676-48420 3.9 (0.154) 4
      35676-48430 4.0 (0.157) 5
      35676-48440 4.1 (0.161) 6
      FOR TMMWV MADE:

      Part Number Thickness
      mm (in.)      		 Mark
      35676-06230 3.5 (0.138) 0
      35676-06240 3.6 (0.142) 1
      35676-06250 3.7 (0.146) 2
      35676-06260 3.8 (0.150) 3
      35676-06270 3.9 (0.154) 4
      35676-06280 4.0 (0.157) 5
      35676-06290 4.1 (0.161) 6
  17. INSPECT CLEARANCE OF C-2 CLUTCH 

    HINT: 

    GTY895120Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    Serial Number

    The component manufacturer (AW (AISIN AW) or TMMWV (TOYOTA)) can be determined based on the serial number as described in the following table.

    Serial Number Factory
    ##6######## AW (AISIN AW)
    ##A######## TMMWV (TOYOTA)
    1. Using a dial indicator, measure the clearance of the C-2 clutch while applying compressed air (approximately 400 kPa (4.1 kgf/cm 2 , 58 psi)).
      GTY698564Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Piston Stroke

      0.8 to 1.0 mm (0.0315 to 0.0394 in.)

      HINT: 

      To find the clearance, measure in at least 3 locations and average the results.

      If the clearance is not as specified, select an appropriate direct clutch flange so that the clearance will be within the specified range.

      Direct Clutch Flange Thickness

      FOR AW (AISIN AW) MADE:

      Part Number Thickness
      mm (in.)      		 Mark
      35675-48370 3.6 (0.142) 0
      35675-48380 3.7 (0.146) 1
      35675-48390 3.8 (0.150) 2
      35675-48400 3.9 (0.154) 3
      35675-48410 4.0 (0.157) 4
      35675-48420 4.1 (0.161) 5
      35675-48430 4.2 (0.165) 6
      FOR TMMWV MADE:

      Part Number Thickness
      mm (in.)      		 Mark
      35675-06140 3.6 (0.142) 0
      35675-06150 3.7 (0.146) 1
      35675-06160 3.8 (0.150) 2
      35675-06170 3.9 (0.154) 3
      35675-06180 4.0 (0.157) 4
      35675-06190 4.1 (0.161) 5
      35675-06200 4.2 (0.165) 6
  18. INSPECT CLEARANCE OF B-2 BRAKE 

    HINT: 

    GTY895120Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    Serial Number

    The component manufacturer (AW (AISIN AW) or TMMWV (TOYOTA)) can be determined based on the serial number as described in the following table.

    Serial Number Factory
    ##6######## AW (AISIN AW)
    ##A######## TMMWV (TOYOTA)
    1. Using a dial indicator, measure the clearance of the B-2 brake while applying compressed air (approximately 200 kPa (2.0 kgf/cm 2 , 29 psi)).
      GTY733601Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Piston Stroke

      1.0 to 1.2 mm (0.0394 to 0.0472 in.)

      HINT: 

      To find the clearance, measure in at least 3 locations and average the results.

      If the clearance is not as specified, select an appropriate 2nd brake flange so that the clearance will be within the specified range.

      HINT: 

      There are 7 2nd brake flanges of different thicknesses available.

      2nd Brake Flange Thickness

      FOR AW (AISIN AW) MADE:

      Part Number Thickness
      mm (in.)      		 Mark
      35678-48040 5.0 (0.197) 0
      35678-48050 5.1 (0.201) 1
      35678-48060 5.2 (0.205) 2
      35678-48070 5.3 (0.209) 3
      35678-48080 5.4 (0.213) 4
      35678-48090 5.5 (0.217) 5
      35678-48100 5.6 (0.220) 6
      FOR TMMWV MADE:

      Part Number Thickness
      mm (in.)      		 Mark
      35678-06210 5.0 (0.197) 0
      35678-06220 5.1 (0.201) 1
      35678-06230 5.2 (0.205) 2
      35678-06240 5.3 (0.209) 3
      35678-06250 5.4 (0.213) 4
      35678-06260 5.5 (0.217) 5
      35678-06270 5.6 (0.220) 6
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