Automatic Transmission Unit Disassembly

Remove the bolt and breather hose.

Remove the nut, washer and control shaft lever.

Using a screwdriver, unstake the lock washer.

Remove the nut and lock washer.

Remove the bolt and park/neutral position switch.

HINT:

Make sure that the manual valve lever shaft has not been rotated prior to installing the park/neutral position switch as the detent spring may become detached from the manual valve lever shaft.

Remove the temperature sensor.

Remove the 2 tube unions.

Remove the O-rings from each tube union.

Remove the bolt and sensor.

Remove the O-ring from the sensor.

Remove the bolt and sensor.

Remove the O-ring from the sensor.

Remove the 6 bolts.

Remove the transmission housing.

Install the transmission case on the overhaul attachment.

Remove the 8 bolts.

Remove the rear transfer adaptor.

Using a screwdriver, pry out the oil seal.

Using a snap ring expander, remove the snap ring.

Remove the sensor rotor and key.

Remove the 19 bolts.

Install the blade of oil pan seal cutter between the transmission case and oil pan. Cut through the seal and remove the oil pan.

NOTICE:

Be careful not to damage the oil pan and flange.

Remove the magnets and use them to collect steel particles.

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): bush wear.
   

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

Remove the oil strainer and 3 gaskets.

Disconnect the 4 connectors from the shift solenoid valves.

Remove the bolt and stopper plate from the case.

Pull out the transmission wire from the transmission case.

Remove the 20 bolts and valve body.

Remove the check ball body and spring.

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

Remove the 2 O-rings from the piston.

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

Remove the 2 O-rings from the piston.

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

Remove the 2 O-rings from the piston.

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

Remove the O-ring from the piston.

Remove the bolt and pull out the plug.

Remove the O-ring from the plug.

Remove the 3 bolts and bracket.

Disconnect the parking lock rod from manual valve lever.

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

Remove the E-ring from the shaft.

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

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.

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

Using a screwdriver, pry out the 2 oil seals.

Stand up the transmission.

Remove the 7 bolts from the transmission case.

Using SST, remove the oil pump.

SST

09350-30020(09350-07020)

Remove the O-ring from the oil pump.

Remove the race from the oil pump.

Remove the overdrive planetary gear and one-way clutch from the transmission case.

Remove the race and assembled bearing and race.

Remove the ring gear from the transmission case.

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

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

SST

09350-30020(09350-06120)

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.)

HINT:

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

Using a screwdriver, pry out the a snap ring.

Remove the overdrive brake pack.

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

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.)

Remove the 2 bolts holding the overdrive support assembly to the case.

Using SST, remove the snap ring.

SST

09350-30020(09350-07060)

Using SST, remove the overdrive support assembly.

SST

09350-30020(09350-07020)

Remove the assembled bearing and race and race from the overdrive support assembly.

Using SST, remove the snap ring.

SST

09350-30020(09350-07060)

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

Remove the 2-O-rings from the cover.

Remove the direct clutch and forward clutch from the case.

Remove the 2 bearings and races.

Remove the direct clutch from the forward clutch.

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

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

Remove the 2nd coast brake band from the case.

Remove the planetary ring gear from the case.

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

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

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

Maximum inside diameter:

24.65mm (0.9705 in.)

Remove the race from the planetary gear.

Using SST, remove the snap ring.

SST

09350-30020(09350-07070)

Remove the planetary gear from the case.

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

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.)

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

Remove the thrust washer.

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.)

Using a screwdriver, pry out the snap ring.

Remove the flange, plates and discs as a set.

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.
   

Using a screwdriver, remove the sleeve.

Using SST and a screwdriver, remove the snap ring.

SST

09350-30020(09350-07060)

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

Remove the assembled thrust bearing and race from the case.

Remove the 2nd brake drum.

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

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.

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

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

SST

09350-30020(09350-07050)

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

SST

09350-30020(09350-07070)

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.

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.)

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.

Remove the O-ring from the brake piston.

Using SST, remove the sleeve.

SST

09350-30020(09350-07080)

Remove the 2 O-rings from the sleeve.

Using SST, remove the brake piston.

SST

09350-30020(09350-07090)

Remove the 2 O-rings from the brake piston.

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

Maximum inside diameter:

38.19 mm (1.5035 in.)