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Automatic Transaxle - Overhaul (FS5A-EL): Other Mazda 3 BL

Automatic Trans 136 illustrations ~4195 words

Cleaning Notes

  1. Clean the transaxle exterior thoroughly with steam, cleaning solvents, or both, before disassembly. WARNING: Using compressed air can cause dirt and other particles to fly out, causing injury to the eyes. Wear protective eye wear whenever using compressed air.
  2. Clean the removed parts with cleaning solvent, and dry with compressed air. Clean out all holes and passages with compressed air, and verify that there are no obstructions.

General notes

  1. The oil pan could contain small chips, shavings, and other particles which may be helpful in inspecting the condition of the transaxle and diagnosing certain problems. To ensure that all foreign particles stay in the oil pan, make sure that the transaxle is never tipped completely over while the oil pan is still installed. Disassemble the transaxle in a clean area (dustproof work space) to prevent entry of dust into the mechanisms. Inspect the individual transaxle components in accordance with the QUICK DIAGNOSIS CHART during disassembly. Use only plastic hammers when applying force to separate the light alloy case joints. Never use rags during disassembly; they may leave particles that can clog fluid passage. Several parts resemble one another; arrange them so that they do not get mixed up. Disassemble the control valve component and thoroughly clean it when the clutch or brake band has burned or when the ATF has degenerated. WARNING: Although the stand has a self-locking brake system, there is a possibility that the brake may not hold when the transaxle is held in a lopsided position on the stand. This would cause the transaxle to turn suddenly, causing serious injury. Never keep the transaxle tilted to one side. Always hold the rotating handle firmly when turning the transaxle.

Scheme 783

Scheme 783: Components

Scheme 784

Scheme 784

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Scheme 787

Scheme 787: Disassembly procedure

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Scheme 831
  1. Remove the torque converter, and immediately turn it so that the hole faces upward This will help to keep any remaining fluid from spilling.
  2. Remove the ATF dipstick and oil filler tube.
  3. Remove the O-ring from the oil filler tube.
  4. Remove the breather hose.
  5. Assemble the SST.
  6. Lift the transaxle and mount it on the SST.
  7. Remove the input/turbine speed sensor.
  8. Remove the O-ring from the input/turbine speed sensor.
  9. Remove the oil pressure switch.
  10. Remove the transaxle range switch.
  11. Remove the vehicle speed sensor.
  12. Remove the O-ring from the vehicle speed sensor.
  13. Remove the intermediate sensor.
  14. Remove the O-ring from the intermediate sensor.
  15. Remove the connector pipe, connector bolt and oil pipe. WARNING: Using compressed air can cause dirt and other particles to fly, out, causing injury to the eyes. Wear protective eye wear whenever using compressed air. CAUTION: Clean the transaxle exterior thoroughly with a steam cleaner or cleaning solvents before removal. If any old sealant gets into the transaxle during installation of the oil cover, trouble may occur in the transaxle. Remove any old sealant from the transaxle case and oil cover, and clean with cleaning fluids.
  16. Remove the oil cover. Examine any material found in the pan or on the magnet to determine the condition of the transaxle. If large amounts of material are found, replace the torque converter and carefully inspect the transaxle for the cause. Clutch facing material Drive plate and brake band wear Steel (magnetic) Bearing, gear, and driven plate wear Aluminum (nonmagnetic) Aluminum part wear
  17. Disconnect the solenoid valve connector.
  18. Remove the bolts as shown in the figure.
  19. Remove the secondary control valve body.
  20. Remove the coupler component.
  21. Remove the O-rings and tubular pins from the transaxle case. WARNING: Using compressed air can cause dirt and other particles to fly, out, causing injury to the eyes. Wear protective eye wear whenever using compressed air. CAUTION: Clean the transaxle exterior thoroughly with a steam cleaner or cleaning solvents before removal. If any old sealant gets into the transaxle during installation of the oil pan, trouble may occur in the transaxle. Remove any old sealant from the transaxle case and oil pan, and clean with cleaning fluids.
  22. Remove the oil pan. Examine any material found in the pan or on the magnet to determine the condition of the transaxle. If large amounts of material are found, replace the torque converter and carefully inspect the transaxle for the cause. Clutch facing material Drive plate and brake band wear Steel (magnetic) Bearing, gear, and driven plate wear Aluminum (nonmagnetic) Aluminum part wear
  23. Disconnect the solenoid valve connector, ground, and TFT sensor.
  24. Remove the oil strainer.
  25. Remove the O-ring from the oil strainer.
  26. Remove the bolts as shown in the figure. NOTE: Remove the control valve body by removing the head of the manual valve from the port of the parking assist lever component.
  27. Remove the Primary control valve body.
  28. Remove the coupler component.
  29. Remove the accumulator component.
  30. Remove the manual shaft. Remove the roll pin using a pin punch. Remove the manual shaft. Remove the O-ring from the manual shaft.
  31. Remove the parking rod lever component.
  32. Remove the band servo component.
  33. Remove the oil pump.
  34. Remove the converter housing by tapping lightly with a plastic hammer.
  35. Remove the forward clutch component.
  36. Remove the differential.
  37. Remove the actuator plate.
  38. Remove the support actuator.
  39. Pull out the parking pawl shaft.
  40. Remove the parking pawl.
  41. Remove the pawl return spring.
  42. Remove the Output gear component.
  43. Remove the Secondary sun gear.
  44. Remove the direct clutch component and one-way clutch No.2.
  45. Remove the Needle bearing, seal rings and spacer.
  46. Remove the reduction brake.(See «REDUCTION BRAKE DISASSEMBLY/ ASSEMBLY»(ref-345239-S35528019482009102000000) .)
  47. Remove the end cover.
  48. Remove the O-rings from the transaxle case.
  49. Remove the band strut.
  50. Remove the 2-4 brake band, and hold it together using a piece of wire as shown in the figure.
  51. Remove the clutch component.
  52. Remove the snap ring.
  53. Remove the rear planetary gear component.
  54. Remove the front sun gear by tapping its end with a flathead screwdriver or similar tool, as shown in the figure.
  55. Remove the forward clutch hub.
  56. Remove the front planetary gear component.
  57. Remove the front internal gear and one-way clutch component.
  58. Remove the locknut. Knock the crimped portion of the locknut outward by using a small chisel and a hammer. Install the SST to the primary gear in the order shown. Tightening torque 19-25 N.m {1.9-2.6 kgf.m, 14-18 ft.lbf} Install the SST to the locknut in the order shown. Remove the locknut.
  59. Remove the primary gear by tapping it with a flathead screwdriver, etc. as shown in the figure.
  60. Remove the bearing and distance piece. CAUTION: Removing the bearing race using a flathead screwdriver can damage the inside of the bearing race. Handle the flathead screwdriver carefully.
  61. Remove torx screws from the converter housing side.
  62. Remove the bearing race.
  63. Remove the bearing race using the SST as shown in the figure.
  64. Remove the bearing using the SST as shown in the figure.

Scheme 832

Scheme 832: ACCUMULATORS DISASSEMBLY/ASSEMBLY
  1. Disassemble in the order indicated in the table.
  2. Assemble in the reverse order of disassembly.

Scheme 833

Scheme 833: Assembly Procedure

Scheme 834

Scheme 834
  1. Measure the spring free length. Accumulator spring (standard) ACCUMULATOR SPRING SPECIFICATIONS Spring Outer diameter mm {in} Free length mm {in} No. of coils Wire diameter mm {in} Servo apply accumulator large spring 21.0 {0.827} 67.8 {2.669} 10.3 3.5 {0.138} Servo apply accumulator small spring 13.0 {0.512} 67.8 {2.669} 17.1 2.2 {0.087} Forward accumulator large spring 21.0 {0.827} 75.0 {2.953} 10.7 2.3 {0.091} Forward accumulator small spring 15.6 {0.614} 49.0 {1.929} 7.7 2.4 {0.094} If not as specified, replace the spring.
  2. Install the forward accumulator small spring, forward accumulator large spring and forward accumulator.
  3. Install the servo apply accumulator small spring, servo apply accumulator large spring and servo apply accumulator.
  1. Select the adjustment shims, referring to Bearing Preload.
  2. If the drive plates or 2-4 brake band are replaced with new ones, soak the new part in ATF for at least two hours before installation.
  3. Before assembly, apply ATF to all seal rings, rotating parts, O-rings, and sliding parts.
  4. All O-rings, seals, and gaskets must be replaced with the new ones included in the overhaul kit.
  5. Use petroleum jelly, not grease, when assembling again.
  6. When it is necessary to replace a bushing, replace the subassembly that includes that bushing.
  7. Assemble the housing within 10 minutes after applying sealant, and allow it to cure for at least 30 minutes after assembly before filling the transaxle with ATF.
WARNINGAlthough the stand has a self-locking brake system, there is a possibility that the brake may not hold when the transaxle is held in a lopsided position on the stand. This would cause the transaxle to turn suddenly, causing serious injury. Never keep the transaxle tilted to one side. Always hold the rotating handle firmly when turning the transaxle.

Scheme 835

Scheme 835: Bearing and race locations

Note. The bearing and race at locations 3, 4, 5, 6 and 7 are one-piece units.

Outer diameter of bearing and race

123456789
Bearing (mm {in})40.0 {1.57}39.0 {1.54}78.2 {3.08}52.0 {2.05}50.0 {1.97}46.5 {1.83}61.0 {2.40}
Race (mm {in})40.2 {1.58}59.0 {2.32}

OUTER DIAMETER OF BEARING AND RACE

Scheme 836

Scheme 836: Components

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Scheme 840: Assembly procedure

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Scheme 910
  1. Measure the bushing of the front sun gear. Front sun gear bushing inner diameter Standard: 18.000-18.018 mm {0.70866-0.70936 in} Maximum: 18.038 mm {0.71016 in}
  2. If not as specified, replace the front sun gear.
  3. Measure the bushing of the end cover. End cover bushing inner diameter Standard: 23.600-23.621 mm {0.92913-0.92995 in} Maximum: 23.641 mm {0.93075 in}
  4. If not as specified, replace the end cover.
  5. Measure the bushing of the secondary sun gear. Secondary sun gear bushing inner diameter Standard: 26.000-26.021 mm {1.02362-1.02445 in} Maximum: 26.041 mm {1.02524 in}
  6. If not as specified, replace the secondary sun gear.
  7. Assemble the SST .
  8. Lift the transaxle case and mount it on the SST . NOTE: If the transaxle case has been newly replaced perform step (9).
  9. Install the oil pipe.
  10. Install the bearing race, then tighten torx screws. Tightening torque 10.8-13.7 N.m {110-140 kgf.cm, 95.5-121 in.lbf}
  11. Install the bearing race to the transaxle case.
  12. Install the locknut. Set the primary gear. Set the distance piece and bearing. Loosely tighten the locknut. Set the SSTs in the order shown. Tighten the locknut from the end cover side to adjust the preload within the specification. Primary gear preload 0.50-0.90 N.m {5.10-9.17 kgf.cm, 4.42-7.96 in.lbf} Stake the locknut. Remove the SST
  13. Install the front internal gear and one-way clutch.
  14. Apply petroleum jelly to the bearing, and secure it to the front planetary gear component.
  15. Install the front planetary gear component.
  16. Apply petroleum jelly to the bearing, and secure it to the front sun gear.
  17. Install the front sun gear.
  18. Install the rear planetary gear. NOTE: Rotate the engine stand so that the oil pan faces downward. Pull the front internal gear and one-way clutch component a little until the groove for the snap ring appears, then install the snap ring.
  19. Install the snap ring.
  20. Rotate the engine stand so that the end cover faces upward, and verify that the snap ring is installed accurately.
  21. Install the band servo component. Install the servo return spring and servo piston. Apply ATF to the O-ring, and install it to the transaxle case. Install the servo retainer. Tightening torque 11-14 N.m {113-142 kgf.cm, 98-123 in.lbf}
  22. Apply petroleum jelly to the bearing, and secure it to the clutch component.
  23. Install the clutch component.
  24. Install the 2-4 brake band.
  25. Select the band strut. Find an appropriate bolt (under head length: 60-70 mm {2.36-2.75 in}) , and tighten the 2-4 brake band with the bolt. Tightening torque 4.9 N.m {50 kgf.cm, 43 in.lbf} Measure the dimension A shown in the figure. Remove the bolt. Measure the dimension B shown in the figure. Calculate according to the formula below. B - A = C (The middle of the under head length) C - 4 = D (The lower limit of under head length) C - 4.7 = E (The upper limit of under head length) Select a band strut whose length should be between D and E. Band strut length for 2-4 brake band servo stroke (mm {in}) BAND STRUT LENGTH SPECIFICATIONS 36.0 {1.417} 36.5 {1.437} 37.0 {1.457} 37.25 {1.467} 37.5 {1.476} 37.75 {1.486} 38.0 {1.496} 38.25 {1.506} 38.5 {1.516} 39.0 {1.535} - - Install the selected band strut. Tightening torque 37-52 N.m {3.8-5.3 kgf.m, 28-38 ft.lbf}
  26. Use the following procedure to adjust the total end play. Install the thickest bearing race (2.6 mm {0.102 in}) to the end cover. Install the end cover to the clutch component. Measure the clearance A between transaxle case and end cover. Calculate according to the formulas below. Select an appropriate bearing race whose bearing thickness matches the calculated limits. A - 2.6 mm {0.102} (Bearing thickness) = B B - 0.25 = C (The lower limit of bearing thickness) B - 0.50 = D (The upper limit of bearing thickness) Select a bearing race whose thickness is between D mm {in} and C mm {in}. Bearing race sizes BEARING RACE SIZES mm {in} 1.8 {0.071} 2.0 {0.079} 2.2 {0.087} 2.4 {0.094} 2.6 {0.102} - CAUTION: The bearing race and end cover may be damaged if the end cover is not installed correctly to the transaxle case. Align the projection of the bearing race within the area of the arrows shown in the figure, and then install the end cover to the transaxle case. Remove the end cover, apply petroleum jelly to the selected bearing race, then install it to the end cover.
  27. Apply ATF to new seal ring, and install it to the end cover. Seal ring inner diameter A: 47.1 mm {1.854 in} B: 55.8 mm {2.197 in}
  28. Apply a light coat of silicone sealant to the contact surfaces of the transaxle case and the end cover.
  29. Apply ATF to the O-ring and install it to the transaxle case.
  30. Install the end cover to the transaxle case. Tightening torque 19-25 N.m {1.9-2.6 kgf.m, 14-18 ft.lbf}
  31. Install the reduction brake to the transaxle case. (See «REDUCTION BRAKE DISASSEMBLY/ASSEMBLY»(ref-345239-S35528019482009102000000) .) NOTE: If the transaxle case has been newly replaced perform Step (32).
  32. Install the needle bearing using the SST as shown in the figure.
  33. Install the spacer and one-way clutch No.2 to the transaxle case.
  34. Apply ATF to new seal ring, and install it to the transaxle case.
  35. Apply petroleum jelly to the needle bearing, and secure it to the transaxle case.
  36. Install the direct clutch component to the transaxle case.
  37. Install the secondary sun gear.
  38. Install the output gear component.
  39. Install the bearing race to the output gear component.
  40. Apply petroleum jelly to the needle bearing, and secure it to the output gear component.
  41. Use the following procedure to adjust the total end play. Measure clearance A between the installation surface and the hole depth of the converter housing. Install the bearing to the output gear component. Measure clearance B between the converter housing installation surface and the bearing. Calculate the total end play according to the following formula: step (1) value - step (3) value = total end play. select the snap ring. Adjust shim size for output gear component total end play ADJUST SHIM SIZE FOR OUTPUT GEAR COMPONENT TOTAL END PLAY total end play {in} Adjust shims sizes mm {in} 1.431-1.481 {0.057-0.058} 1.20 {0.047} 1.381-1.431 {0.055-0.056} 1.15 {0.045} 1.331-1.381 {0.053-0.054} 1.10 {0.043} 1.281-1.331 {0.051-0.052} 1.05 {0.041} 1.231-1.281 {0.049-0.050} 1.00 {0.039} 1.181-1.231 {0.047-0.048} 0.95 {0.037} 1.131-1.181 {0.045-0.046} 0.90 {0.035} 1.081-1.131 {0.043-0.044} 0.85 {0.033} 1.031-1.081 {0.041-0.042} 0.80 {0.031} 0.981-1.031 {0.039-0.040} 0.75 {0.029} 0.931-0.981 {0.037-0.038} 0.70 {0.028} 0.881-0.931 {0.035-0.036} 0.65 {0.026} 0.831-0.881 {0.033-0.034} 0.60 {0.024} 0.781-0.831 {0.031-0.032} 0.55 {0.022} 0.731-0.781 {0.029-0.030} 0.50 {0.020} Install the selected adjustment shim to the converter housing.
  42. Install the bearing using the SST as shown in the figure. Press-in force 8.8 kN {897 kgf, 1978 lbf}
  43. Install the pawl return spring to the transaxle case.
  44. Install the packing pawl and parking pawl shaft to the transaxle case.
  45. Install the pawl return spring to the parking pawl and parking pawl shaft.
  46. Install the support plate to the transaxle case.
  47. Install the actuator plate to the transaxle case. Tightening torque 11-14 N.m {113-142 kgf.cm, 98-123 in.lbf}
  48. Install the differential.
  49. Install the forward clutch hub.
  50. Install the forward clutch component.
  51. Apply a light coat of silicone sealant to the contact surfaces of the converter housing and the transaxle case.
  52. Install the converter housing. Tightening torque 19-25 N.m {1.9-2.6 kgf.m, 14-18 ft-lbf}
  53. Install the SST into the differential side gears.
  54. Apply ATF to the new O-ring and install it to the oil pump.
  55. Install the oil pump. Tightening torque 19-25 N.m {1.9-2.6 kgf.m, 14-18 ft.lbf}
  56. Install the parking rod lever component. Tightening torque 19-25 N.m {1.9-2.6 kgf.m, 14-18 ft.lbf}
  57. Apply ATF to the new O-ring and install it to the manual shaft.
  58. Install the manual shaft. Install the manual shaft to the manual plate and detent bracket component. Install the knock pin.
  59. Install the accumulator component.
  60. Install the coupler component. CAUTION: Make sure that the head of the manual valve and the parking rod are assembled properly. If they are not, the ranges cannot be changed.
  61. Install the primary control valve body. Tightening torque 7.8-10.8 N.m {80-110 kgf.cm, 69-95.5 in.lbf} Bolt length (measured from below the head) B: 40 mm {1.575 in} No mark: 70 mm {2.756 in}
  62. Apply ATF to the new O-ring and install it to the oil strainer.
  63. Install the oil strainer.
  64. Match the harness colors, then connect the solenoid connector and TFT sensor. SOLENOID VALVE DESCRIPTION Solenoid valve Color of connector (harness side) Pressure control solenoid A Black Shift solenoid A White Shift solenoid B Blue Shift solenoid C Green Shift solenoid D White Shift solenoid E Black
  65. Install the ground. Tightening torque 7.8-10.8 N.m {80-110 kgf.cm, 69-95.5 in.lbf} WARNING: Using compressed air can cause dirt and other particles to fly out, causing injury to the eyes. Wear protective eye wear whenever using compressed air. CAUTION: Clean the transaxle exterior thoroughly with a steam cleaner or cleaning solvents before removal. If any old sealant gets into the transaxle during installation of the oil pan, trouble may occur in the transaxle case and oil pan, and clean with cleaning fluids.
  66. Apply a light coat of silicone sealant to the contact surfaces of oil pan and transaxle case.
  67. Install the oil pan. Tightening torque 6-8 N.m {62-81 kgf.cm, 54-70 in.lbf}
  68. Apply ATF to the new O-ring and install it to the transaxle case.
  69. Install the tubular pins.
  70. Install the coupler component.
  71. Install the secondary control valve body and ground. Tightening torque 7.8-10.8 N.m {80-110 kgf.cm, 69-95.5 in.lbf} Bolt length (measured from below the head) B: 40 mm {1.575 in} C: 50 mm {1.969 in}
  72. Match the harness colors, then connect the solenoid connector. SOLENOID VALVE DESCRIPTION Solenoid valve Color of connector (harness side) Pressure control solenoid B White Shift solenoid F Black WARNING: Using compressed air can cause dirt and other particles to fly out, causing injury to the eyes. Wear protective eye wear whenever using compressed air. CAUTION: Clean the transaxle exterior thoroughly with a steam cleaner or cleaning solvents before removal. If any old sealant gets into the transaxle during installation of the oil cover, trouble may occur in the transaxle case and oil pan, and clean with cleaning fluids.
  73. Apply a light coat of silicone sealant to the contact surfaces of oil cover and transaxle case.
  74. Install the oil cover. Tightening torque 7.8-10.8 N.m {80-110 kgf.cm, 69-95.5 in.lbf}
  75. Install the oil pipe and connector bolt. Tightening torque 24-35 N.m {2.4-3.6 kgf.cm, 18-26 in.lbf}
  76. Install the connector pipe. Tightening torque 24-35 N.m {2.4-3.6 kgf.cm, 18-26 in.lbf}
  77. Apply ATF to the new O-ring and install it to the intermediate sensor.
  78. Install the intermediate sensor. Tightening torque 8-11 N.m {82-112 kgf.cm, 71-97 in.lbf}
  79. Apply ATF to the new O-ring and install it to the vehicle speed sensor.
  80. Install the vehicle speed sensor. Tightening torque 8-11 N.m {82-112 kgf.cm, 71-97 in.lbf}
  81. Apply ATF to the new O-ring and install it to the input/turbine speed sensor.
  82. Install the oil pressure switch. Tightening torque 17.1-22.1 N.m {1.75-2.25 kgf.m, 12.7-16.2 ft.lbf}
  83. Install the input/turbine speed sensor. Tightening torque 8-11 N.m {82-112 kgf.cm, 71-97 in.lbf}
  84. Install the transaxle range switch. Rotate the manual shaft to the N position. Turn the protrusion a resistance between the terminals B and C become 750 ohms. Install the TR switch while aligning the protrusion and groove as shown. hand-tighten the TR switch mounting bolts. Inspect the resistance between the terminals B and C. If not as specified, readjust the TR switch. Resistance 750 ohms Tighten the TR switch mounting bolts Tightening torque 8-11 N.m {82-112 kgf.cm, 71-97 in.lbf} CAUTION: Do not use an impact wrench. Hold the manual shaft lever when removing the manual shaft nut, or the transaxle may be damaged. Install the manual shaft lever and the washer. Set the adjustable wrench as shown to hold the manual shaft lever, and tighten the manual shaft nut. Tightening torque 32-46 N.m {3.2-4.7 kgf.m, 24-33 ft.lbf}
  85. Remove the transaxle from the SST.
  86. Apply ATF to the new O-ring and install it to the oil filler tube.
  87. Install the oil dipstick and oil filler tube to the transaxle. Tightening torque 7.8-10.8 N.m {80-110 kgf.cm, 69-95.5 in.lbf}
  88. Drain any ATF remaining in the torque converter.
  89. Pour in solvent (approx. 0.5 L {0.53 US qt, 0.44 Imp qt}).
  90. Shake the torque converter to clean the inside.
  91. Pour out the solvent.
  92. Pour the ATF.
  93. Install the torque converter by aligning its gap to the oil pump inner rotor gap as shown in the figure.
  94. To ensure that the torque converter is installed accurately, measure distance A between the end of the torque converter and the end of the converter housing. Between the end of the torque converter and the end of the converter housing Distance A: 21.4 mm {0.84 in}

Clutch clearance

Measure the direct clutch clearance.

Scheme 911

Scheme 911: Clutch clearance

Scheme 912

Scheme 912

Scheme 913

Scheme 913
  1. Install the direct clutch in the transaxle case, and set the dial gauge.
  2. Secure the direct clutch by lightly pressing down with a press or similar tool.
  3. Apply compressed air to the part indicated in the figure and let the direct clutch piston stroke three times. Air pressure 392-441 kPa {4.0-4.5 kgf/cm 2 , 57-63 psi}
  4. Apply compressed air and operate the direct clutch piston. Read the value when the indicator of the dial gauge stops.
  5. Release the compressed air and read the dial gauge when the direct clutch piston is not operating.
  6. Calculate the direct clutch clearance according to the following formula: step (4) value - step (5) value = direct clutch clearance.
  7. Measure the clearances at four locations (90° apart) by following the steps from (3) to (6). Verify that the average value is within the specification below. Direct clutch clearance Standard: 1.10-1.40 mm {0.043-0.055 in}
  8. If not as specified, replace parts as necessary. (See «DIRECT CLUTCH DISASSEMBLY/ASSEMBLY»(ref-345239-S10232402322009102000000) .)

Scheme 914

Scheme 914: Brake operation
  1. Set the direct clutch drum onto the transaxle case. CAUTION: Applying compressed air to the assembled clutch pack for longer than 3 s at a time will damage the seal. Do not apply compressed air for more than the aforementioned time when testing the system.
  2. Inspect the brake operation by applying compressed air as shown. Air pressure 392 kPa {4.0 kgf/cm 2 , 57 psi} max.
  3. If not as specified, replace parts as necessary. (See «REDUCTION BRAKE DISASSEMBLY/ASSEMBLY»(ref-345239-S35528019482009102000000) .)

Brake clearance

Measure the reduction brake clearance.

Scheme 915

Scheme 915: Brake clearance

Scheme 916

Scheme 916

Scheme 917

Scheme 917
  1. Set the dial gauge to the reduction brake.
  2. Set the measuring point of the dial gauge to the retaining plate.
  3. Apply compressed air to the part indicated in the figure and let the reduction brake piston stroke three times. Air pressure 392 kPa {4.0 kgf/cm 2 , 57 psi} max.
  4. Apply compressed air and operate the reduction brake piston. Read the value when the indicator of the dial gauge stops.
  5. Release the compressed air and read the dial gauge when the reduction brake piston is not operating.
  6. Calculate the reduction brake clearance according to the following formula: Step (4) value-Step (5) value= reduction brake clearance.
  7. Measure the clearances at four locations (90° apart) by following the steps from (3) to (6). Verify that the average value is within the specification below. Reduction brake clearance 1.50-1.80 mm {0.059-0.070 in}
  8. If not as specified, replace parts as necessary. (See «REDUCTION BRAKE DISASSEMBLY/ASSEMBLY»(ref-345239-S35528019482009102000000) .)

Differential Preinspection Backlash

Scheme 918

Scheme 918
  1. Measure the backlash of the side gear. Differential backlash Standard: 0.05-0.15 mm {0.002-0.005 in} Maximum: 0.5 mm {0.020 in}
  2. If not specified, replace the differential. (See «DIFFERENTIAL DISASSEMBLY/ ASSEMBLY»(ref-345239-S32641026962009102000000) .)