AUTOMATIC TRANSMISSION UNIT > DISASSEMBLY

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1. REMOVE DRAIN PLUG SUB-ASSEMBLY


2. REMOVE BREATHER HOSE


C115790E01


3. REMOVE TRANSMISSION CONTROL SHAFT LEVER LH


D028070E01

  1. Remove the nut, washer and control shaft lever.



4. REMOVE PARK/NEUTRAL POSITION SWITCH ASSEMBLY


G034858E01

  1. Using a screwdriver, unstake the lock washer.

  1. Remove the nut, lock washer and grommet.

  1. Remove the bolt and park/neutral position switch.



5. REMOVE ATF TEMPERATURE SENSOR


Q003891E01

  1. Remove the bolt and sensor.

  1. Remove the O-ring from the sensor.



6. REMOVE OIL COOLER TUBE UNION


Q003892E01

  1. Remove the 2 tube unions.

  1. Remove the O-rings from each tube union.



7. REMOVE OVERDRIVE DIRECT CLUTCH SPEED SENSOR


Q003894E01

  1. Remove the bolt and sensor.

  1. Remove the O-ring from the sensor.



8. REMOVE NO. 2 VEHICLE SPEED SENSOR


G035550E01

  1. Remove the bolt and sensor.

  1. Remove the O-ring from the sensor.



9. REMOVE AUTOMATIC TRANSMISSION HOUSING


D028078E01

  1. Remove the 6 bolts.

  1. Remove the transmission housing.



10. FIX TRANSMISSION CASE


AT05092E01

  1. Install the transmission case on the overhaul attachment.



11. REMOVE REAR ADAPTOR TRANSFER


D028071E01

  1. Remove the 8 bolts.

  1. Remove the rear adaptor transfer.



12. REMOVE TRANSFER CASE ADAPTOR REAR OIL SEAL


D027909E01

  1. Using a screwdriver, pry out the oil seal.



13. REMOVE SENSOR ROTOR


AT05751E01

  1. Using a snap ring expander, remove the snap ring.



    G035544E01

  1. Remove the sensor rotor and key.



14. REMOVE AUTOMATIC TRANSMISSION OIL PAN SUB-ASSEMBLY


D028705E01

NOTICE:
Do not turn the transmission over as this will contaminate the valve body with foreign matter located at the bottom of the pan.

  1. Remove the 19 bolts.



    Q007487E01

  1. Install the blade of SST between the transmission case and the oil pan, and cut off the applied sealer.

    SST
    09032-00100  

    NOTICE:
    Be careful not to damage the oil pan and flange.

  1. Remove the pan by lifting the transmission case.



15. INSPECT AUTOMATIC TRANSMISSION OIL PAN SUB-ASSEMBLY


D001124E03

  1. Remove the magnets and use them to collect steel particles.

  1. 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.

    1. Steel (magnetic): bearing, gear and clutch plate wear.
    2. Brass (non-magnetic): bushng wear.



16. REMOVE VALVE BODY OIL STRAINER ASSEMBLY


D005550E01

  1. Remove the 4 bolts holding the oil strainer to the valve body.

  1. Remove the oil strainer and 5 gaskets.



    D009120E01

  1. Pry the pipe ends with a large screwdriver and remove the pipe.



17. REMOVE TRANSMISSION WIRE


D029778E01

  1. Disconnect the 4 connectors from the shift solenoid valves.



    AT05066E01

  1. Remove the bolt and stopper plate from the case.

  1. Pull out the transmission wire from the transmission case.

  1. Remove the O-ring from the transmission wire.



18. REMOVE TRANSMISSION VALVE BODY ASSEMBLY


D029011E01

  1. Remove the 20 bolts and valve body.



19. REMOVE CHECK BALL BODY


AT04847E01

  1. Remove the check ball body and spring.



20. REMOVE B-2 ACCUMULATOR PISTON


D006514E01

  1. Apply compressed air to the oil hole to remove the B-2 accumulator piston and spring.

  1. Remove the 2 O-rings from the piston.



21. REMOVE C-2 ACCUMULATOR PISTON


D006514E02

  1. Apply compressed air to the oil hole to remove the C-2 accumulator piston and spring.

  1. Remove the 2 O-rings from the piston.



22. REMOVE B-0 ACCUMULATOR PISTON


D006515E01

  1. Apply compressed air to the oil hole to remove the B-0 accumulator piston and spring.

  1. Remove the 2 O-rings from the piston.



23. REMOVE C-0 ACCUMULATOR PISTON


D006516E01

  1. Apply compressed air to the oil hole to remove the C-0 accumulator piston.

  1. Remove the O-ring from the piston.



24. REMOVE TRANSMISSION CASE PLUG


D005553E01

  1. Remove the bolt and pull out the plug.

  1. Remove the O-ring from the plug.



25. REMOVE PARKING LOCK PAWL BRACKET


AT05103E01

  1. Remove the 3 bolts and bracket.



26. REMOVE PARKING LOCK ROD


AT05120E01

  1. Disconnect the parking lock rod from manual valve lever.



27. REMOVE PARKING LOCK PAWL SHAFT


Z006720E01

  1. Pull out the parking lock pawl shaft from the front side, then remove the lock pawl and spring.

  1. Remove the E-ring from the shaft.



28. REMOVE MANUAL VALVE LEVER SHAFT


Z006721E01

  1. Using a hammer and screwdriver, cut off the spacer and remove the it from the shaft.



    AT05105E01

  1. Using a pin punch and hammer, tap out the spring pin.

    HINT:
    Slowly drive out the spring pin so that it does not fall into the transmission case.

  1. Pull out the manual valve lever shaft through the case, and remove the manual valve lever.



29. REMOVE MANUAL VALVE LEVER SHAFT OIL SEAL


G034854E01

  1. Using a screwdriver, pry out the 2 oil seals.



30. REMOVE OIL PUMP ASSEMBLY


AT05122E01

  1. Stand up the transmission.

  1. Remove the 7 bolts from the transmission case.



    AT05123E01

  1. Using SST, remove the oil pump.

    SST
    09350-30020   (09350-07020)

  1. Remove the O-ring from the oil pump.



    AT08431E01

  1. Remove the race from the oil pump.



31. REMOVE OVERDRIVE PLANETARY GEAR ASSEMBLY AND ONE-WAY CLUTCH ASSEMBLY


Q000619E01

  1. Remove the planetary gear, direct clutch and one-way clutch from the transmission case.



    AT03148E02

  1. Remove the race and assembled bearing and race.



32. REMOVE OVERDRIVE PLANETARY RING GEAR


AT05146E01

  1. Remove the ring gear from the transmission case.



    G035541E02

  1. Remove the assembled bearing and race and race from the overdrive planetary ring gear.



33. INSPECT OVERDRIVE BRAKE PISTON


AT05282E01

  1. Place SST and a dial indicator onto the overdrive brake piston.

    SST
    09350-30020   (09350-06120)



    AT05147E01

  1. Measure the stroke while applying and releasing compressed air (392 kPa (4.0 kgf/cm2, 57 psi)).

    Piston stroke:
    1.75 to 2.05 mm (0.0689 to 0.0807 in.)

    If the piston stroke is not as specified, parts may have been assembled incorrectly. Check and reassemble again.

    HINT:
    1. If the piston stroke is still outside the standard, select another flange.
    2. There are 7 different thicknesses for the flange.

    Flange thickness: 
    No.
    		Thickness
    		No.
    		Thickness
    77
    		3.3 mm (0.130 in.)
    		81
    		3.8 mm (0.150 in.)
    78
    		3.5 mm (0.138 in.)
    		82
    		3.9 mm (0.154 in.)
    79
    		3.6 mm (0.142 in.)
    		83
    		4.0 mm (0.157 in.)
    80
    		3.7 mm (0.146 in.)




34. REMOVE OVERDRIVE BRAKE CLUTCH DISC


AT05109E01

  1. Using a screwdriver, pry out the a snap ring.



    Q000637E04

  1. Remove the overdrive brake pack.



35. INSPECT PISTON STROKE OF 2ND COAST BRAKE


AT05216E01

  1. Using a water proof pen, place a mark on the 2nd coast brake piston rod as shown in the illustration.



    AT05217E01

  1. Using SST, measure the piston stroke while applying and releasing a compressed air (392 kPa (4.0 kgf/cm2, 57 psi)).

    SST
    09240-00020  

    Piston stroke:
    1.5 to 3.0 mm (0.059 to 0.118 in.)

    If the stroke is not as specified, inspect the brake band.



36. REMOVE OVERDRIVE SUPPORT ASSEMBLY


AT05148E01

  1. Remove the 2 bolts holding the overdrive brake assembly to the case.



    AT05249E01

  1. Using SST, remove the snap ring.

    SST
    09350-30020   (09350-07060)



    AT05211E01

  1. Using SST, remove the overdrive brake assembly.

    SST
    09350-30020   (09350-07020)



    AT05110E01

  1. Remove the assembled bearing and race and race from the overdrive brake assembly.



37. REMOVE 2ND COAST BRAKE PISTON ASSEMBLY


AT05127E01

  1. Using SST, remove the snap ring.

    SST
    09350-30020   (09350-07060)



    AT05280E01

  1. Apply compressed air to the oil hole to remove the 2nd coast brake cover, piston assembly and spring.

  1. Remove the 2-O-rings from the cover.



38. REMOVE DIRECT CLUTCH ASSEMBLY


AT05149E01

  1. Remove the direct clutch and forward clutch from the case.



    AT03149E01

  1. Remove the 2 bearings and races.



39. REMOVE FORWARD CLUTCH ASSEMBLY


AT05262E01

  1. Remove the direct clutch from the forward clutch.



    AT05259E03

  1. Remove the assembled bearing and race, thrust washer and race from the forward clutch.



40. REMOVE 2ND COAST BRAKE BAND


AT05111E01

  1. Using a screwdriver, pry out the E-ring from the pin.



    Q004030E01

  1. Remove the 2nd coast brake band from the case.



41. REMOVE FRONT PLANETARY RING GEAR


AT05128E01

  1. Remove the planetary ring gear from the case.



    Q000841E02

  1. Remove the assembled bearing and race, bearing and race from the planetary ring gear.



    Z005131E01

  1. With wooden blocks or equivalent under the output shaft, stand the transmission on the output shaft.



42. INSPECT FRONT PLANETARY RING GEAR


AT08187E01

  1. Using a dial indicator, measure the inside diameter of the planetary ring gear bush.

    Maximum inside diameter:
    24.65mm (0.9705 in.)

    If the inside diameter is greater than the maximum, replace the planetary ring gear.



43. REMOVE FRONT PLANETARY GEAR


D029744E01

  1. Remove the race from the planetary gear.



    D029740E01

  1. Using SST, remove the snap ring.

    SST
    09350-30020   (09350-07070)



    D029741E01

  1. Remove the planetary gear from the case.



    D029742E01

  1. Using a screwdriver, remove the bearing and race from the planetary gear.



44. INSPECT FRONT PLANETARY PINION GEAR THRUST CLEARANCE


D029743E01

  1. Using a feeler gauge, measure the pinion gear thrust clearance.

    Standard clearance:
    0.20 to 0.60 mm (0.0079 to 0.0236 in.)

    Maximum clearance:
    0.65 mm (0.0256 in.)

    If the clearance is greater than the maximum, replace the planetary gear.



45. REMOVE PLANETARY SUN GEAR ASSEMBLY AND ONE WAY CLUTCH ASSEMBLY


Q000837E01

  1. Remove the sun gear and one-way clutch from the case.

  1. Remove the thrust washer.



46. INSPECT PACK CLEARANCE OF 2ND BRAKE


AT05215E01

  1. Using a feeler gauge, measure the clearance between the snap ring and flange.

    Clearance:
    0.62 to 1.98 mm (0.0244 to 0.0780 in.)

    If the clearance is not as specified, inspect the discs.



47. REMOVE 1ST AND REVERSE BRAKE CLUTCH DISC


AT05476E01

  1. Using a screwdriver, pry out the snap ring.



    AT05398E01

  1. Remove the flange, plates and discs as a set.



48. INSPECT PACK CLEARANCE OF 1ST AND REVERSE BRAKE


AT08223E01

  1. Using a feeler gauge, measure the clearance between the plate and 2nd brake drum.

    Clearance:
    0.70 to 1.22 mm (0.0276 to 0.048 in.)

    HINT:
    1. If the clearance is not as specified, select another flange.
    2. There are 8 different thicknesses for the flange.

    Flange thickness: 
    No.
    		Thickness
    		No.
    		Thickness
    67
    		 5.4mm (0.213 in.)
    		52
    		 4.6 mm (0.181 in.)
    66
    		 5.2 mm (0.205 in.)
    		53
    		 4.4 mm (0.173 in.)
    50
    		 5.0 mm (0.197 in.)
    		54
    		 4.2 mm (0.165 in.)
    51
    		 4.8 mm (0.189 in.)
    		55
    		 4.0 mm (0.157 in.)



49. REMOVE 2ND BRAKE PISTON SLEEVE


AT05279E01

  1. Using a screwdriver, remove the sleeve.



50. REMOVE REAR PLANETARY GEAR ASSEMBLY


AT05460E01

  1. Using SST and a screwdriver, remove the snap ring.

    SST
    09350-30020   (09350-07060)



    AT05158E01

  1. Remove the rear planetary, 2nd brake drum, 1st and reverse brake pack, No. 2 one-way clutch and output shaft.



    AT05132E01

  1. Remove the assembled thrust bearing and race from the case.



    AT08183E01

  1. Remove the 2nd brake drum.



    AT08208E01

  1. Remove the cushion plate, flange, plates and discs of the 1st and reverse brake.



51. REMOVE LEAF SPRING


AT05107E01


52. INSPECT 1ST AND REVERSE BRAKE CLUTCH DISC


AT06460E01

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

    NOTICE:
    Before assembling new discs, soak them in ATF for at least 15 minutes.



53. REMOVE BRAKE DRUM GASKET


AT04444E01


54. INSPECT PISTON STROKE OF 1ST AND REVERSE BRAKE


AT05258E01

  1. Make sure the 1st and reverse brake pistons move smoothly when applying and releasing compressed air into the transmission case.



55. REMOVE 1ST AND REVERSE BRAKE RETURN SPRING SUB-ASSEMBLY


AT08336E01

  1. Place SST on the 1st and reverse brake return spring, and compress the brake return spring.

    SST
    09350-30020   (09350-07050)

  1. Using SST, remove the snap ring and brake return spring.

    SST
    09350-30020   (09350-07070)

  1. Hold the No. 2 1st and reverse brake piston by hand, and apply compressed air to the transmission case to remove the No. 2 1st and reverse brake piston.



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


Q000777E01

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

    Standard free length:
    12.9 mm (0.508 in.)

    If the length is not as specified, replace the spring sub-assembly.



57. REMOVE 1ST AND REVERSE BRAKE PISTON NO. 2


AT05375E01

  1. Hold the No. 2 1st and reverse brake piston and apply compressed air into the transmission case to remove the brake piston.

    HINT:
    If the piston does not pop out with compressed air, lift the piston out with needle-nose pliers.

  1. Remove the O-ring from the brake piston.



58. REMOVE BRAKE REACTION SLEEVE


AT08335E01

  1. Using SST, remove the sleeve.

    SST
    09350-30020   (09350-07080)

  1. Remove the 2 O-rings from the sleeve.



59. REMOVE NO. 1 1ST AND REVERSE BRAKE PISTON


AT08334E01

  1. Using SST, remove the brake piston.

    SST
    09350-30020   (09350-07090)

  1. Remove the 2 O-rings from the brake piston.



60. INSPECT TRANSMISSION CASE BUSHING


AT08224E01

  1. Using a cylinder gauge, measure the inside diameter of the transmission case rear bush.

    Maximum inside diameter:
    38.19 mm (1.5035 in.)

    If the inside diameter is greater than the maximum, replace the transmission case.