AUTOMATIC TRANSMISSION UNIT > DISASSEMBLY

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1. REMOVE TRANSMISSION CONTROL SHAFT LEVER LH


D027971E01

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



2. REMOVE PARK/NEUTRAL POSITION SWITCH ASSEMBLY


D027903E01

  1. Using a screwdriver, pry out the lock washer.

  1. Remove the nut, lock washer and bolt.

  1. Remove the park/neutral position switch.



3. REMOVE OIL COOLER TUBE UNION

  1. Remove the 2 oil cooler tube unions.

  1. Remove the O-ring from the oil cooler tube union.



4. REMOVE SPEED SENSOR


C111258

  1. Remove the 2 bolts and 2 transmission revolution sensors.

  1. Remove the O-ring from each sensor.



5. REMOVE AUTOMATIC TRANSAXLE BREATHER TUBE


D027970E02

  1. Remove the 3 bolts.

  1. Remove the breather tube.

  1. Remove the O-ring from each tube.



6. REMOVE AUTOMATIC TRANSMISSION HOUSING


C111207

  1. Remove the 10 bolts.

  1. Remove the transmission housing.



7. REMOVE EXTENSION HOUSING SUB-ASSEMBLY


D027972E01

  1. Remove the 6 bolts.

  1. Remove the extension housing assembly.

    HINT:
    Use a brass bar and hammer to remove the extension housing assembly.

  1. Remove the gasket from the extension housing assembly.



    D029874E01

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

  1. Remove the thrust needle roller bearing and 2 bearing races.



8. REMOVE EXTENSION HOUSING DUST DEFLECTOR


D027976E01

  1. Using a brass bar and hammer, remove the extension housing dust deflector.



9. REMOVE AUTOMATIC TRANSMISSION EXTENSION HOUSING OIL SEAL


D027977E01

  1. Using SST, tap out the oil seal.

    SST
    09308-00010  



10. FIX AUTOMATIC TRANSMISSION CASE SUB-ASSEMBLY


D027911E01

  1. Install the transmission case on the overhaul attachment.



11. REMOVE AUTOMATIC TRANSMISSION OIL PAN SUB-ASSEMBLY

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

  1. Remove the drain plug and 20 bolts.



12. INSPECT AUTOMATIC TRANSMISSION OIL PAN SUB-ASSEMBLY


D001124E01

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

  1. Carefully lock 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): bushing wear



13. REMOVE VALVE BODY OIL STRAINER ASSEMBLY


D012703E01

  1. Turn over the transmission.

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

  1. Remove the O-ring form the valve body oil strainer assembly.



14. REMOVE TRANSMISSION WIRE


D012704E01

  1. Remove the ATF temperature sensor.

  1. Remove the bolt and clamp.

  1. Disconnect the 7 connectors from the shift solenoid valves.



    D027912E01

  1. Remove the bolt from the case.

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

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



15. REMOVE TRANSMISSION VALVE BODY ASSEMBLY


D012705E01

  1. Remove the 19 bolts.

  1. Remove the valve body assembly.



16. REMOVE TRANSAXLE CASE GASKET


D027968E03

  1. Remove the 3 transaxle case gaskets.



17. REMOVE BRAKE DRUM GASKET


D027969E01

  1. Remove the 3 brake drum gaskets.



18. REMOVE CHECK BALL BODY


D027914E04

  1. Remove the check ball body and spring.



19. REMOVE C-2 ACCUMULATOR PISTON


D027915E01

  1. Applying compressed air to the oil hole, and remove the C2 accumulator piston and spring.

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

    NOTICE:
    Be careful as the C-3 and B-3 accumulator piston may jump out.



20. REMOVE B-3 ACCUMULATOR PISTON


D027915E01

  1. Applying compressed air to the oil hole, and remove the C2 accumulator piston and spring.

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

    NOTICE:
    Be careful as the C-3 accumulator piston may jump out.



21. REMOVE C-3 ACCUMULATOR PISTON


D027916E01

  1. Applying compressed air to the oil hole, and remove the B-3 accumulator piston and spring.

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



22. REMOVE C-1 ACCUMULATOR VALVE


D027917E01

  1. Remove the C-1 accumulator valve and 2 springs.



23. REMOVE PARKING LOCK PAWL BRACKET


D012708E01

  1. Remove the 3 bolts and parking lock pawl bracket.



24. REMOVE PARKING LOCK ROD SUB-ASSEMBLY


D012709E01

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



25. REMOVE PARKING LOCK PAWL SHAFT


D028846E01

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

  1. Remove the E-ring from the shaft.



26. REMOVE MANUAL VALVE LEVER SUB-ASSEMBLY


D027918E01

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



    D027919E01

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



27. REMOVE MANUAL VALVE LEVER SHAFT OIL SEAL


D027920E01

  1. Using a screwdriver, remove the 2 oil seals.



28. REMOVE OIL PUMP ASSEMBLY


D027921E01

  1. Remove the 10 bolts holding the oil pump from the transmission case.



    D027922E02

  1. Using SST, remove the oil pump.

    SST
    09350-30020   (09350-07020)



    D028809E01

  1. Remove the No. 1 thrust bearing race from the front oil pump.



29. REMOVE CLUTCH DRUM AND INPUT SHAFT ASSEMBLY


D027923E01

  1. Remove the clutch drum and input shaft drum assembly from the transmission case.



    D027924E03

  1. Remove the clutch drum thrust washer and thrust needle roller bearing.



30. INSPECT 1-WAY NO. 2 CLUTCH ASSEMBLY


D027993E01

  1. Hold the Reverse clutch hub and turn the No. 2 1-way clutch assembly

  1. The No. 2 1-way clutch assembly turns freely clockwise and locks when turned counterclockwise.



31. REMOVE 1-WAY NO. 2 CLUTCH ASSEMBLY


D027994E01

  1. Remove the No. 2 1-way clutch assembly and No. 2 clutch drum thrust washer from the clutch drum and input shaft assembly.



32. REMOVE NO. 3 BRAKE SNAP RING


D027925E01

  1. Using a screwdriver, remove the No. 3 brake snap ring from the case.



33. REMOVE NO. 3 BRAKE DISC


D027926E03

  1. Remove the flange and cushion plate the 4 discs and the 4 plates from the case.



34. INSPECT NO. 3 BRAKE DISC


D001216E01

  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.



35. REMOVE 2ND BRAKE PISTON HOLE SNAP RING


D027927E03

  1. Using SST, remove the snap ring.

    SST
    09350-30020   (09350-07060)



36. REMOVE 1-WAY CLUTCH ASSEMBLY


D027928E01

  1. Remove the 1-way clutch assembly and the No. 1 planetary carrier thrust washer from the case.



37. REMOVE 2ND BRAKE CYLINDER


D027929E01

  1. Remove the 2nd brake cylinder from the case.



38. REMOVE 2ND BRAKE PISTON


D028817E03

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

    SST
    09351-40010  



    D028545E01

  1. Hold the 2nd brake piston and apply compressed air (392 kPa, 4.0 kgf/cm2, 57 psi) to the brake cylinder to remove the 2nd brake piston.



    D028546E03

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



39. INSPECT NO. 3 BRAKE PISTON RETURN SPRING SUB-ASSEMBLY


D029828E01

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

    Standard free length:
    15.72 mm (0.619 in.)



40. REMOVE FRONT PLANETARY GEAR ASSEMBLY


D028544E01

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

    Standard clearance:
    0.2 to 0.60 mm (0.008 to 0.024 in.)
    Maximum clearance:
    0.65 mm (0.026 in.)

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



    D028543E01

  1. Using a dial indicator, measure the inside diameter of the front planetary gear bushing.

    Maximum inside diameter:
    57.48 mm (2.263 in.)

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



41. INSPECT FRONT PLANETARY GEAR ASSEMBLY


D028544E01

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

    Standard clearance:
    0.2 to 0.60 mm (0.008 to 0.024 in.)
    Maximum clearance:
    0.65 mm (0.026 in.)

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



    D028543E01

  1. Using a dial indicator, measure the inside diameter of the front planetary gear bushing.

    Maximum inside diameter:
    57.48 mm (2.263 in.)

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



42. INSPECT 1-WAY CLUTCH ASSEMBLY


D028542E01

  1. Install the 1-way clutch assembly to the 1-way clutch inner race.

  1. Hold the 1-way clutch inner race and turn the 1-way clutch assembly.

  1. Check that the 1-way clutch assembly turns freely counterclockwise and locks when turned clockwise.

  1. Remove the 1-way clutch assembly from the 1-way clutch inner race.



43. REMOVE FRONT PLANETARY RING GEAR


D027932E01

  1. Remove the front planetary ring gear and bearing from the transmission case.



44. REMOVE CENTER PLANETARY RING GEAR


D028540E01

  1. Using a screwdriver, remove the snap ring.



    D028541E01

  1. Remove the center planetary ring gear and front planetary ring gear flange from the front planetary ring gear.



45. REMOVE NO. 1 BRAKE DISC


D027933E03

  1. Remove the flange, 3 discs and 3 plates from the case.



46. INSPECT NO. 1 BRAKE DISC


D001216E01

  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.



47. REMOVE BRAKE PISTON RETURN SPRING SNAP RING


D027934E01

  1. Using a screwdriver, remove the brake piston return spring snap ring from the case.



48. REMOVE BRAKE PISTON RETURN SPRING SUB-ASSEMBLY


D027935E01

  1. Remove the brake piston return spring and No. 1 the brake piston with the No. 1 brake cylinder from the transmission case.



49. INSPECT BRAKE PISTON RETURN SPRING SUB-ASSEMBLY


D003830E01

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

    Standard free length:
    17.05 mm (0.671 in.)



50. REMOVE NO. 1 BRAKE PISTON


D027936E01

  1. Hold the brake piston No. 1 and apply compressed air (392 kPa, 4 kgf/cm2, 57 psi) to the transmission case to remove the No. 1 brake piston.

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

  1. Remove the 2 O-rings from the No. 1 brake piston.



51. REMOVE NO. 2 BRAKE DISC


D027937E01

  1. Using a screwdriver, remove the snap ring from the case.



    D027938E03

  1. Remove the flange, the brake piston return spring, the 3 discs and the 3 plates from the case.



52. INSPECT NO. 2 BRAKE DISC


D001216E01

  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. INSPECT NO.2 BRAKE PISTON RETURN SPRING SUB-ASSEMBLY


D029829E01

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

    Standard free length:
    17.45 mm (0.687 in.)



54. REMOVE NO. 2 BRAKE PISTON


D027939E01

  1. Hold the No. 2 brake piston and apply compressed air (392 kPa, 4 kgf/cm2, 57 psi) to the transmission case to remove the No. 2 brake piston.

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

  1. Remove the 2 O-rings from the No. 2 brake piston.



55. REMOVE CENTER PLANETARY GEAR ASSEMBLY


D027940E01

  1. Remove the center planetary gear assembly, the planetary sun gear and the No. 4 thrust bearing race from the case.



56. INSPECT CENTER PLANETARY GEAR ASSEMBLY


D028533E01

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

    Standard clearance:
    0.12 to 0.68 mm (0.005 to 0.027 in.)
    Maximum clearance:
    0.73 mm (0.029 in.)

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



57. REMOVE INTERMEDIATE SHAFT


D027941E01

  1. Using a screwdriver, remove the snap ring from the case.



    D027942E01

  1. Remove the intermediate shaft with the No. 3 1- way clutch assembly from the case.



58. INSPECT NO. 3 1-WAY CLUTCH ASSEMBLY


D028532E01

  1. Hold the rear planetary ring gear flange sub-assembly turn the 1-way clutch assembly.

  1. Check that the 1-way clutch assembly turns freely counterclockwise and locks when turned clockwise.



59. REMOVE NO. 3 1-WAY CLUTCH ASSEMBLY


D027964E01

  1. Remove the No. 3 1-way clutch assembly and the 1 way clutch inner race from the intermediate shaft.



60. REMOVE REAR PLANETARY RING GEAR FLANGE SUB-ASSEMBLY


D027965E04

  1. Remove the No. 8 thrust bearing race thrust needle roller bearing, the No. 7 thrust bearing race and the planetary ring gear flange from the intermediate shaft.



61. INSPECT REAR PLANETARY RING GEAR FLANGE SUB-ASSEMBLY


D028531E01

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

    Maximum inside diameter:
    32.175 mm (1.267 in.)

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



62. INSPECT INTERMEDIATE SHAFT


D028529E01

  1. Using a dial indicator, check the intermediate shaft runout.

    Maximum runout:
    0.08 mm (0.003 in.)

    NOTICE:
    If the bend exceeds the specification, replace the intermediate shaft with anew one.



    D028530E02

  1. Using a micrometer, check the outer diameter of the intermediate shaft positions shown in the diagram.

    Standard diameter:
    A:
    25.962 to 25.975 mm (1.022 to 1.023 in.)
    B:
    25.962 to 25.975 mm (1.022 to 1.023 in.)
    C:
    32.062 to 32.075 mm (1.262 to 1.263 in.)
    D:
    32.062 to 32.075 mm (1.262 to 1.263 in.)

    Standard diameter:
    A:
    25.912 mm (1.020 in.)
    B:
    25.912 mm (1.020in.)
    C:
    32.012 mm (1.260 in.)
    D:
    32.012 mm (1.260 in.)

    NOTICE:
    If the outer diameter is outside the standard, replace the intermediate shaft with the new one.



63. REMOVE BRAKE PLATE STOPPER SPRING


D027943E01

  1. Remove the brake plate stopper spring from the case.



64. REMOVE NO. 4 BRAKE DISC


D027944E03

  1. Remove the 7 plates, the 8 discs and the 2 flanges from the case.



65. INSPECT NO. 4 BRAKE DISC


D001216E01

  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.



66. REMOVE REAR PLANETARY GEAR ASSEMBLY


D027945E01

  1. Remove the rear planetary gear assembly from the case.



    D027946E02

  1. Remove the thrust bearing race No. 9 and the thrust needle roller bearing from the rear planetary gear assembly.



    D027947E01

  1. Remove the thrust needle roller bearing from the case.



67. INSPECT REAR PLANETARY GEAR ASSEMBLY


D028531E01

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

    Maximum inside diameter:
    32.175 mm (1.267 in.)

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



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


D028083E01

  1. Place SST on the spring retainer and compress the brake return spring.

    SST
    09350-30020   (09350-07050)

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

    SST
    09350-30020   (09350-07070)



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


D029830E01

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

    Standard free length:
    23.74 mm (0.935 in.)



70. REMOVE 1ST AND REVERSE BRAKE PISTON


D027948E01

  1. Hold the No. 2 brake piston and apply compressed air (392 kPa, 4 kgf/cm2, 57 psi) to the transmission case to remove the No. 2 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 No. 2 brake piston.



71. REMOVE BRAKE REACTION SLEEVE


D028079E04

  1. Using SST, remove the reaction sleeve.

    SST
    09350-30020   (09350-07080)

  1. Remove the O-ring from the reaction sleeve.



72. REMOVE NO. 4 BRAKE PISTON


D001240E03

  1. Using SST, remove the No. 4 bbrake piston.

    SST
    09350-30020   (09350-07090)

  1. Remove the 2 O-rings from the No. 4 piston.