K121 CVT  CONTINUOUSLY VARIABLE TRANSAXLE UNIT  INSPECTION  

Using a dial indicator, measure the input shaft end play.

Standard Input Shaft End Play:

0.345 to 1.357 mm (0.0136 to 0.0534 in.)

Use the removed oil cleaner (CVT) magnets to collect any steel chips. Examine the chips and particles in the transaxle housing and on the oil cleaner (CVT) magnets to determine what type of wear might be found in the continuously variable transaxle assembly.

Result:

Steel (magnetic):

Bearing, gear and plate wear

Brass (non-magnetic):

Bushing wear

Install the forward multiple disc clutch assembly to the stator (CVT) shaft assembly.

Using a dial indicator, measure the clearance of the C-1 clutch while applying compressed air (approximately 250 kPa (2.5 kgf/cm², 36 psi)).

Pack Clearance (Reference):

0.45 to 0.75 mm (0.0177 to 0.0295 in.)

NOTICE:

Be careful as fluid may spray when applying compressed air.

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 forward clutch flange so that the clearance will be within the specified range.

Forward Clutch Flange Thickness:

Part Number	Thickness mm (in.)	Mark
35635-12280	3.3 (0.130)	B
35635-12290	3.4 (0.134)	C
35635-12300	3.5 (0.138)	D
35635-12310	3.6 (0.142)	E
35635-12320	3.7 (0.146)	F
35635-12330	3.8 (0.150)	G

Check if the contact surfaces of the forward multiple disc clutch clutch discs, forward multiple disc clutch clutch plates and forward clutch flange are worn or burnt.

If necessary, replace them.

NOTICE:

·

If the lining of any disc is peeled off or discolored, or even if part of the groove is damaged, replace all discs.

·

Before installing new discs, soak them in Toyota Genuine CVT fluid FE for at least 15 minutes.

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

Standard Free Length:

18.54 mm (0.730 in.)

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

Using a feeler gauge, measure the clearance between the planetary carrier and the pinion gears at 6 points.

Standard Clearance:

0.16 to 0.61 mm (0.00630 to 0.0240 in.)

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

Using a dial indicator, measure the clearance of the B-1 brake while applying compressed air (approximately 250 kPa (2.5 kgf/cm2, 36 psi)).

Pack Clearance:

0.588 to 1.272 mm (0.0232 to 0.0500 in.)

NOTICE:

Be careful as fluid may spray when applying compressed air.

HINT:

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

If the clearance is more than specified, replace the brake flange, No. 1 brake discs and No. 1 brake plates.

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

If necessary, replace them.

NOTICE:

·

If the lining of any disc is peeled off or discolored, or even if part of the groove is damaged, replace all discs.

·

Before installing new discs, soak them in Toyota Genuine CVT fluid FE for at least 15 minutes.

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

Standard Free Length:

17.56 mm (0.691 in.)

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