REPLACEMENT — Part 2 Lexus RX III

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1. REMOVE BREATHER PLUG HOSE Using a screwdriver, remove the breather plug hose from the transaxle case. Using a screwdriver, remove the No. 1 breather plug (ATM) and No. 2 breather plug (ATM) from the breather plug hose. TEXT IN ILLUSTRATION *1 No. 1 Breather Plug (ATM) *2 Breather Plug Hose *3 No. 2 Breather Plug (ATM) *4 O-ring Using a screwdriver, remove the O-ring from the No. 2 breather plug (ATM).
2. REMOVE PARK/NEUTRAL POSITION SWITCH ASSEMBLY Remove the nut, washer and control shaft lever from the control shaft. Remove the 2 bolts and park/neutral position switch assembly from the transaxle case. NOTE: Before removing the park/neutral position switch, remove any dirt or rust on the installation portion of the control shaft. Be sure to remove the switch straight along the shaft while being careful not to deform the plate spring that supports the shaft. If the plate spring is deformed, the park/neutral position switch cannot be reinstalled correctly.
3. REMOVE OIL COOLER TUBE UNION (OUTLET OIL COOLER UNION) Remove the oil cooler tube union (outlet oil cooler union) from the transaxle case. Remove the O-ring from the oil cooler tube union (outlet oil cooler union).
4. REMOVE OIL COOLER TUBE UNION (INLET OIL COOLER UNION) Loosen the nut while holding the oil cooler tube union (inlet oil cooler union). Remove the oil cooler tube union (inlet oil cooler union) from the transaxle case. Remove the O-ring from the oil cooler tube union (inlet oil cooler union).
5. REMOVE NO. 1 TRANSAXLE CASE PLUG Remove the 3 No. 1 transaxle case plugs from the transaxle case. Using a screwdriver, remove the 3 O-rings from the 3 No. 1 transaxle case plugs. Using a hexagon wrench (6 mm), remove the 3 hexagon bolts from the transaxle housing. Remove the gasket from each of the 3 hexagon bolts.
6. SUPPORT AUTOMATIC TRANSAXLE ASSEMBLY Support the transaxle assembly on wooden blocks.
7. REMOVE AUTOMATIC TRANSAXLE OIL PAN SUB-ASSEMBLY Using a hexagon wrench (6 mm), remove the overflow plug from the automatic transaxle oil pan sub-assembly. Remove the gasket from the overflow plug. Using a hexagon wrench (6 mm), remove the No. 1 transmission oil filler tube from the automatic transaxle assembly. Remove the 18 bolts, automatic transaxle oil pan sub-assembly and automatic transaxle oil pan gasket from the automatic transaxle assembly. Remove the 2 transmission oil cleaner magnets from the automatic transaxle oil pan sub-assembly. TEXT IN ILLUSTRATION *1 Magnet
8. INSPECT TRANSMISSION OIL CLEANER MAGNET See step 1
9. REMOVE VALVE BODY OIL STRAINER ASSEMBLY Remove the 2 bolts and oil strainer assembly from the valve body assembly. Remove the O-ring from the oil strainer assembly. TEXT IN ILLUSTRATION *1 O-ring
10. REMOVE TRANSMISSION VALVE BODY ASSEMBLY Remove the 11 bolts and valve body assembly from the transaxle case. NOTE: When removing the transmission valve body assembly, be careful not to allow the transmission revolution sensor and the transaxle case to interfere with each other.
11. REMOVE TRANSAXLE CASE GASKET Remove the 2 gaskets from the transaxle case.
12. INSPECT INPUT SHAFT SUB-ASSEMBLY See step 2
13. REMOVE REAR TRANSAXLE COVER SUB-ASSEMBLY Remove the refill plug from the rear transaxle cover sub-assembly. Remove the gasket from the refill plug. Remove the 2 No. 1 automatic transaxle case plugs from the rear transaxle cover sub-assembly. Using a screwdriver, remove the 2 O-rings from the 2 No. 1 automatic transaxle case plugs. Remove the 14 bolts from the rear transaxle cover sub-assembly. Using a brass bar and a hammer, tap on the circumference of the rear transaxle cover sub-assembly to remove the rear transaxle cover sub-assembly from the transaxle case. Using a screwdriver, remove the 3 O-rings from the transaxle case. Using a screwdriver, remove the 2 oil seal rings from the rear transaxle cover sub-assembly. TEXT IN ILLUSTRATION *1 Oil Seal Ring *2 Thrust Needle Roller Bearing *3 Thrust Needle Roller Race Remove the thrust needle roller bearing and thrust needle roller race from the rear transaxle cover sub-assembly. Using a "TORX" wrench (T30), remove the 2 "TORX" screws and rear transaxle cover plate from the rear transaxle cover sub-assembly. Using SST, remove the needle roller bearing from the rear transaxle cover sub-assembly. TEXT IN ILLUSTRATION *1 Turn *2 Hold SST: 09319-60020
14. REMOVE DIRECT MULTIPLE DISC CLUTCH ASSEMBLY Remove the direct multiple disc clutch assembly from the transaxle case. TEXT IN ILLUSTRATION *1 Direct Multiple Disc Clutch Assembly *2 Thrust Needle Roller Bearing Remove the thrust needle roller bearing from the direct multiple disc clutch assembly.
15. REMOVE DIRECT MULTIPLE DISC CLUTCH SNAP RING Using a screwdriver, remove the snap ring from the direct multiple disc clutch assembly. Remove the No. 2 direct clutch piston from the direct multiple disc clutch assembly. Using a screwdriver, remove the intermediate shaft oil seal from the direct multiple disc clutch assembly. TEXT IN ILLUSTRATION *1 Intermediate Shaft Oil Seal Using a screwdriver, remove the O-ring from the direct multiple disc clutch assembly. TEXT IN ILLUSTRATION *2 O-ring
16. REMOVE NO. 2 CLUTCH DISC Remove the clutch flange, 3 clutch discs and 3 clutch plates from the direct multiple disc clutch assembly. TEXT IN ILLUSTRATION *1 Clutch Plate *2 Clutch Disc *3 Clutch Flange
17. INSPECT NO. 2 CLUTCH DISC See step 3
18. REMOVE REAR PLANETARY SUN GEAR ASSEMBLY Using a snap ring expander, remove the snap ring from the direct multiple disc clutch assembly. Remove the rear planetary sun gear assembly from the direct multiple disc clutch assembly. Remove the thrust needle roller bearing and thrust needle roller race from the direct multiple disc clutch assembly. TEXT IN ILLUSTRATION *1 Thrust Needle Roller Bearing *2 Thrust Needle Roller Race
19. INSPECT REAR PLANETARY SUN GEAR ASSEMBLY See step 8
20. REMOVE NO. 1 CLUTCH DISC Using 2 screwdrivers, remove the 2 snap rings from the direct multiple disc clutch assembly. Remove the clutch flange, 4 clutch discs and 4 clutch plates from the direct multiple disc clutch assembly. TEXT IN ILLUSTRATION *1 Clutch Flange *2 Clutch Plate *3 Clutch Disc
21. INSPECT NO. 1 CLUTCH DISC See step 5
22. REMOVE TRANSAXLE HOUSING Remove the 20 bolts from the transaxle housing. Using a brass bar and a hammer, tap on the circumference of the transaxle housing to remove the transaxle housing from the transaxle case.
23. REMOVE COUNTER DRIVEN GEAR FRONT TAPERED ROLLER BEARING OUTER RACE Using SST, remove the counter driven gear front tapered roller bearing outer race and shim from the transaxle housing. SST: 09308-00010
24. REMOVE DIFFERENTIAL GEAR LUBE APPLY TUBE Remove the bolt, clamp and differential gear lube apply tube from the transaxle housing.
25. REMOVE FRONT OIL PUMP ASSEMBLY Remove the 7 bolts and front oil pump from the transaxle case. Remove the O-ring from the front oil pump assembly. TEXT IN ILLUSTRATION *1 O-ring Remove the thrust needle roller bearing and thrust needle roller race from the carrier lock nut. Remove the O-ring from the transaxle case. TEXT IN ILLUSTRATION *1 Thrust Needle Roller Bearing *2 Thrust Needle Roller Race *3 O-ring
26. REMOVE FRONT OIL PUMP BODY O-RING
27. REMOVE NO. 3 BRAKE DISC Using a screwdriver, remove the snap ring from the oil pump assembly. TEXT IN ILLUSTRATION *1 Snap Ring Remove the 2 No. 3 brake flanges, 3 No. 3 brake discs and 2 No. 3 brake plates from the oil pump assembly. TEXT IN ILLUSTRATION *1 No. 3 Brake Flange *2 No. 3 Brake Plate *3 No. 3 Brake Disc
28. INSPECT NO. 3 BRAKE DISC See step 6
29. REMOVE UNDERDRIVE PLANETARY GEAR ASSEMBLY Remove the underdrive planetary gear assembly from the front oil pump assembly.
30. REMOVE NO. 3 BRAKE HUB Remove the No. 3 brake hub from the underdrive planetary gear assembly. Remove the thrust needle roller bearing and thrust needle roller race from the underdrive planetary gear assembly. TEXT IN ILLUSTRATION *1 Thrust Needle Roller Race *2 Thrust Needle Roller Bearing
31. REMOVE UNDERDRIVE PLANETARY RING GEAR Using needle-nose pliers, remove the snap ring from the underdrive planetary ring gear. TEXT IN ILLUSTRATION *1 Snap Ring Remove the underdrive planetary ring gear from the underdrive planetary gear assembly. TEXT IN ILLUSTRATION *2 Underdrive Planetary Ring Gear
32. REMOVE PLANETARY SUN GEAR SUB-ASSEMBLY While expanding the snap ring with snap ring pliers, remove the planetary sun gear from the underdrive planetary gear assembly. TEXT IN ILLUSTRATION *1 Planetary Sun Gear Sub-assembly Remove the snap ring from the underdrive planetary gear assembly. TEXT IN ILLUSTRATION *2 Underdrive Planetary Gear Assembly *3 Snap Ring
33. INSPECT UNDERDRIVE PLANETARY GEAR ASSEMBLY See step 7
34. INSPECT PLANETARY SUN GEAR SUB-ASSEMBLY See step 4
35. REMOVE INPUT SHAFT SUB-ASSEMBLY Remove the input shaft sub-assembly from the front oil pump assembly. Remove the thrust needle roller bearing and thrust needle roller race from the input shaft. TEXT IN ILLUSTRATION *1 Thrust Needle Roller Race *2 Thrust Needle Roller Bearing Using a screwdriver, remove the 3 input shaft oil seal rings from the input shaft. TEXT IN ILLUSTRATION *3 Input Shaft Oil Seal Ring *4 Input Shaft
36. REMOVE UNDERDRIVE PLANETARY SUN GEAR Remove the underdrive planetary sun gear from the oil pump assembly. TEXT IN ILLUSTRATION *1 Underdrive Planetary Sun Gear Remove the thrust needle roller bearing from the oil pump assembly. TEXT IN ILLUSTRATION *2 Thrust Needle Roller Bearing
37. REMOVE NO. 1 BRAKE DISC Using a screwdriver, remove the 2 snap rings and brake snap ring stopper from the oil pump assembly. TEXT IN ILLUSTRATION *1 Snap Ring *2 Brake Snap Ring Stopper Remove the No. 1 brake flange, 4 No. 1 brake discs, and 4 No. 1 brake plates from the oil pump assembly. TEXT IN ILLUSTRATION *1 No. 1 Brake Flange *2 No. 1 Brake Plate *3 No. 1 Brake Disc
38. INSPECT NO. 1 BRAKE DISC See step 9
39. REMOVE 2ND BRAKE PISTON RETURN SPRING SUB-ASSEMBLY Remove the 3 2nd brake piston return springs from the oil pump assembly.
40. INSPECT 2ND BRAKE PISTON RETURN SPRING SUB-ASSEMBLY See step 10
41. REMOVE NO. 1 BRAKE PISTON Holding the oil pump assembly by hand, apply compressed air (392 kPa, 4.0 kgf/cm 2 , 57 psi) to the oil pump assembly to remove the No. 1 brake piston. Using a screwdriver, remove the 2 O-rings from the No. 1 brake piston. TEXT IN ILLUSTRATION *1 O-ring
42. REMOVE FRONT DIFFERENTIAL CASE Remove the front differential case from the transaxle case.
43. REMOVE COUNTER DRIVE GEAR NUT Using SST and a hammer, unstake the counter drive gear nut. SST: 09930-00010 Turn the manual valve lever 2 notches counterclockwise to set it to the P position as shown in the illustration. Using SST, remove the counter drive gear nut from the planetary gear assembly. SST: 09387-00130
44. REMOVE COUNTER DRIVEN GEAR Turn the manual valve lever 2 notches clockwise to set it to the N position as shown in the illustration. Remove the counter driven gear from the transaxle case.
45. REMOVE COUNTER DRIVEN GEAR FRONT TAPERED ROLLER BEARING Using SST, remove the counter driven gear front tapered roller bearing from the counter driven gear. TEXT IN ILLUSTRATION *1 Turn *2 Hold SST: 09950-00020 SST: 09950-00030 SST: 09950-60010 09951-00400
46. REMOVE COUNTER DRIVEN GEAR REAR TAPERED ROLLER BEARING Using SST, remove the counter driven gear rear tapered roller bearing and differential drive pinion from the counter driven gear. TEXT IN ILLUSTRATION *1 Turn *2 Hold SST: 09950-40011 09951-04010 09952-04010 09953-04020 09954-04010 09955-04071 09957-04010 09958-04011 SST: 09950-60010 09951-00320
47. REMOVE PAWL SHAFT CLAMP Remove the bolt and pawl shaft clamp from the transaxle case.
48. REMOVE PAWL STOPPER PLATE Remove the 2 bolts and pawl stopper plate from the transaxle case.
49. REMOVE PARKING LOCK SLEEVE Remove the parking lock sleeve from the transaxle case.
50. REMOVE PARKING LOCK PAWL Remove the spring, parking lock pawl pin, parking lock pawl shaft and parking lock pawl from the transaxle case. TEXT IN ILLUSTRATION *1 Parking Lock Pawl Shaft *2 Parking Lock Pawl *3 Spring *4 Parking Lock Pawl Pin
51. REMOVE COUNTER DRIVEN GEAR REAR TAPERED ROLLER BEARING OUTER RACE Using SST, remove the counter driven gear rear tapered roller bearing outer race from the transaxle case. SST: 09308-00010
52. REMOVE ONE-WAY CLUTCH ASSEMBLY Using a screwdriver, remove the snap ring from the transaxle case. Remove the one-way clutch assembly with the planetary ring gear from the transaxle case. TEXT IN ILLUSTRATION *1 One-way Clutch Assembly Remove the thrust needle roller bearing from the planetary gear assembly. TEXT IN ILLUSTRATION *2 Thrust Needle Roller Bearing
53. INSPECT ONE-WAY CLUTCH ASSEMBLY See step 11
54. REMOVE PLANETARY RING GEAR Remove the planetary ring gear from the one-way clutch assembly. TEXT IN ILLUSTRATION *1 One-way Clutch Assembly *2 Planetary Ring Gear
55. REMOVE PLANETARY RING GEAR FLANGE Using a screwdriver, remove the snap ring from the planetary ring gear. TEXT IN ILLUSTRATION *1 Snap Ring Remove the planetary ring gear flange from the planetary ring gear. TEXT IN ILLUSTRATION *2 Planetary Ring Gear Flange *3 Planetary Ring Gear
56. REMOVE NO. 2 BRAKE DISC Using a screwdriver, remove the snap ring from the transaxle case. Remove the brake flange, 5 brake discs and 5 brake plates from the transaxle case. TEXT IN ILLUSTRATION *1 Brake Flange *2 Brake Plate *3 Brake Disc
57. INSPECT NO. 2 BRAKE DISC See step 13
58. REMOVE 1ST AND REVERSE BRAKE RETURN SPRING SUB-ASSEMBLY Using a screwdriver, remove the snap ring from the transaxle case. Remove the 1st and reverse brake return spring from the transaxle case.
59. INSPECT 1ST AND REVERSE BRAKE RETURN SPRING SUB-ASSEMBLY See step 14
60. REMOVE NO. 2 BRAKE PISTON Apply compressed air (392 kPa, 4.0 kgf/cm 2 , 57 psi) to the ATF hole to remove the No. 2 brake piston from the transaxle case. Using a screwdriver, remove the 2 O-rings from the No. 2 brake piston. TEXT IN ILLUSTRATION *1 O-ring
61. REMOVE FRONT PLANETARY GEAR ASSEMBLY Using SST and a press, remove the planetary gear assembly from the transaxle case. SST: 09950-60010 09951-00580 SST: 09950-70010 09951-07100
62. REMOVE COUNTER DRIVE GEAR NOTE: Perform this procedure only when the counter drive gear bearing or transaxle case is replaced. Using SST and a press, remove the counter drive gear and bearing inner race (rear side) from the transaxle case. SST: 09950-60020 09951-00710 SST: 09950-70010 09951-07100 As shown in the illustration, tighten the 3 bolts evenly and leave a clearance of approximately 20.0 mm (0.787 in.) between the counter drive gear and bearing inner race (front side). Using SST, remove the bearing inner race (front side) from the counter drive gear. TEXT IN ILLUSTRATION *1 Turn *2 Hold SST: 09950-00020 SST: 09950-00030 SST: 09950-60020 09951-00710
63. REMOVE NO. 3 BRAKE PISTON Using a screwdriver, remove the snap ring from the transaxle case. Remove the brake piston return spring from the transaxle case. TEXT IN ILLUSTRATION *1 Brake Piston Return Spring Remove the No. 3 brake piston from the transaxle case. TEXT IN ILLUSTRATION *2 No. 3 Brake Piston
64. REMOVE MANUAL DETENT SPRING SUB-ASSEMBLY Remove the bolt, cover and manual detent spring sub-assembly from the transaxle case.
65. REMOVE PARKING LOCK ROD SUB-ASSEMBLY Remove the parking lock rod sub-assembly from the parking lock lever sub-assembly. HINT: Align the slot with the notches on the parking lock lever sub-assembly to remove the parking lock rod sub-assembly.
66. REMOVE MANUAL VALVE LEVER SHAFT Using needle-nose pliers, remove the manual valve lever shaft retainer spring from the transaxle case. Using a screwdriver, slide the spacer of the manual valve lever sub-assembly. Using a pin punch (3 mm) and hammer, drive out the slotted spring pin from the manual valve lever sub-assembly. HINT: To prevent the pin from falling into the case, drive the pin until it has cleared the manual valve lever shaft. Using a screwdriver, slide the spacer of the parking lock lever sub-assembly. Using a pin punch (3 mm) and hammer, drive out the slotted spring pin from the parking lock lever sub-assembly. HINT: To prevent the pin from falling into the case, drive the pin until it has cleared the manual valve lever shaft. Remove the manual valve lever shaft, manual valve lever sub-assembly, parking lock lever sub-assembly and 2 spacers from the transaxle case.
67. REMOVE MANUAL VALVE LEVER SHAFT OIL SEAL Using a screwdriver, remove the manual valve lever shaft oil seal from the transaxle case.

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1. INSPECT TRANSMISSION OIL CLEANER MAGNET Use the removed magnets to collect any steel chips. Examine the chips and particles in the pan and on the magnets to determine what type of wear has occurred in the transaxle: Result Steel (magnetic) Bearing, gear and plate wear Brass (non-magnetic) Bushing wear
2. INSPECT INPUT SHAFT SUB-ASSEMBLY Using a dial indicator, measure the input shaft end play. End play 0.012 to 1.250 mm (0.000473 to 0.0492 in.)
3. INSPECT NO. 2 CLUTCH DISC Check if the contact surfaces of the discs, plates and flange are worn or burnt. NOTE: 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.
4. INSPECT PLANETARY SUN GEAR SUB-ASSEMBLY Using a dial indicator, measure the inside diameter of the bushings of the planetary sun gear. Standard inside diameter 25.525 to 25.546 mm (1.0049 to 1.0057 in.) Maximum inside diameter 25.546 mm (1.0057 in.) If the inside diameter is greater than the maximum, replace the planetary sun gear.
5. INSPECT NO. 1 CLUTCH DISC Check if the contact surfaces of the discs, plates and flange are worn or burnt. NOTE: 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.
6. INSPECT NO. 3 BRAKE DISC Check if the contact surfaces of the discs, plates and flanges are worn or burnt. NOTE: 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.
7. INSPECT UNDERDRIVE PLANETARY GEAR ASSEMBLY Using a feeler gauge, measure the clearance between the underdrive planetary gear and the pinion gear at 4 points. Standard clearance 0.18 to 0.54 mm (0.00709 to 0.0213 in.) If the clearance is greater than the standard clearance, replace the underdrive planetary gear.
8. INSPECT REAR PLANETARY SUN GEAR ASSEMBLY Using a dial indicator, measure the inside diameter of the bushing of the rear planetary sun gear sub-assembly. Standard inside diameter 25.580 to 25.601 mm (1.0071 to 1.0079 in.) Maximum inside diameter 25.601 mm (1.0079 in.) If the inside diameter is greater than the maximum, replace the rear planetary sun gear assembly.
9. INSPECT NO. 1 BRAKE DISC Check if the contact surfaces of the discs, plates and flange are worn or burnt. NOTE: 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 2ND BRAKE PISTON RETURN SPRING SUB-ASSEMBLY Using a vernier caliper, measure the free length of the 3 2nd brake piston return springs including the spring seats. Standard free length 23.85 mm (0.939 in.) If the free length is shorter than the standard free length, replace the 2nd brake piston return spring.
11. INSPECT ONE-WAY CLUTCH ASSEMBLY Temporarily install the one-way clutch assembly to the planetary ring gear. 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.
12. INSPECT PLANETARY GEAR ASSEMBLY Using a feeler gauge, measure the clearance between the planetary gear case and each pinion gear at points A and B. - Standard Clearance Point A 0.23 to 0.59 mm (0.00906 to 0.0232 in.) Point B 0.16 to 0.66 mm (0.00630 to 0.0259 in.) If the clearance is greater than the standard clearance, replace the planetary gear assembly.
13. INSPECT NO. 2 BRAKE DISC Check if the contact surfaces of the discs, plates and flange are worn or burnt. NOTE: 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.
14. INSPECT 1ST AND REVERSE BRAKE RETURN SPRING SUB-ASSEMBLY 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 (0.621 in.) If the free length is shorter than the standard free length, replace the 1st and reverse brake return spring.
15. INSPECT CLEARANCE OF NO. 2 BRAKE Using a dial indicator, measure the clearance of the No. 2 brake while applying compressed air (200 kPa, 2.0 kgf/cm 2 , 29 psi). Standard clearance 0.884 to 1.196 mm (0.0348 to 0.0471 in.) HINT: Measure the clearance at 3 points where the 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. HINT: There are 5 flanges of different thicknesses. NO. 2 BRAKE FLANGE THICKNESS: MM (IN.) Mark Thickness 40 4.0 (0.157) 41 4.1 (0.161) 42 4.2 (0.165) 43 4.3 (0.169) 44 4.4 (0.173)
16. INSPECT CLEARANCE OF NO. 1 BRAKE Using a dial indicator, measure the clearance of the No. 1 brake while applying compressed air (200 kPa, 2.0 kgf/cm 2 , 29 psi). Standard clearance 0.807 to 0.974 mm (0.0318 to 0.0383 in.) HINT: Measure the clearance at 3 points where the 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. HINT: There are 6 flanges of different thicknesses. NO. 1 BRAKE FLANGE THICKNESS: MM (IN.) Mark Thickness 30 3.0 (0.118) 31 3.1 (0.122) 32 3.2 (0.126) 33 3.3 (0.130) 34 3.4 (0.134) 35 3.5 (0.138)
17. INSPECT CLEARANCE OF NO. 3 BRAKE Using a vernier caliper and a 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. HINT: Measure dimension A at 3 points where the flange diameter is approximately 166 mm (6.54 in.) and calculate the average. Using a vernier caliper and a straightedge, measure the distance shown in the illustration (Dimension B). HINT: Measure dimension B at 3 points where the No. 3 brake diameter is approximately 166 mm (6.54 in.) and calculate the average. Calculate the clearance value using the following formula: Clearance = Dimension B - Dimension A Standard clearance 0.599 to 0.761 mm (0.0236 to 0.0300 in.) If the clearance is not as specified, select an appropriate brake flange so that the clearance will be within the specified range. HINT: There are 6 flanges of different thicknesses. NO. 3 BRAKE FLANGE THICKNESS: MM (IN.) Mark Thickness 38 3.80 (0.150) 39 3.90 (0.154) 40 4.00 (0.157) 41 4.10 (0.161) 42 4.20 (0.165) 43 4.30 (0.169)
18. INSPECT CLEARANCE OF NO. 1 CLUTCH DISC Install the direct multiple disc clutch assembly onto the rear transaxle cover sub-assembly. Using a dial indicator, measure the No. 1 clutch pack clearance while applying and releasing compressed air (200 kPa, 2.0 kgf/cm 2 , 29 psi). HINT: Measure the clearance at 3 points where the flange diameter is approximately 152 mm (5.98 in.) and calculate the average. Pack clearance 0.806 to 0.974 mm (0.0317 to 0.0383 in.) If the pack clearance is not as specified, select an appropriate No. 1 clutch flange so that the pack clearance will be within the specified range. HINT: There are 6 flanges of different thicknesses. NO. 1 CLUTCH FLANGE THICKNESS: MM (IN.) Mark Thickness 30 3.0 (0.118) 31 3.1 (0.122) 32 3.2 (0.126) 33 3.3 (0.130) 34 3.4 (0.134) 35 3.5 (0.138)
19. INSPECT CLEARANCE OF NO. 2 CLUTCH DISC Install the direct multiple disc clutch assembly onto the rear transaxle cover sub-assembly. Using a dial indicator, measure the No. 2 clutch pack clearance while applying and releasing compressed air (200 kPa, 2.0 kgf/cm 2 , 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. Pack clearance 0.544 to 0.744 mm (0.0214 to 0.0293 in.) If the pack clearance is not as specified, select an appropriate No. 2 clutch flange so that the pack clearance will be within the specified range. HINT: There are 6 flanges of different thicknesses. NO. 2 CLUTCH FLANGE THICKNESS: MM (IN.) Mark Thickness 30 3.0 (0.118) 31 3.1 (0.122) 32 3.2 (0.126) 33 3.3 (0.130) 34 3.4 (0.134) 35 3.5 (0.138)

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