Automatic Transmission Unit Disassembly

Remove the nut, washer and control shaft lever LH.

Using a screwdriver, pry out the lock washer.

Remove the nut, lock washer and bolt.

Remove the 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 2 oil cooler tube unions.

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

Remove the 2 bolts and 2 sensors.

Remove the O-ring from each sensor.

Remove the 3 bolts.

Remove the breather tube.

Remove the O-ring from each tube.

Remove the 10 bolts.

Remove the transmission housing.

Remove the 6 bolts.

Remove the extension housing assembly.

HINT:

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

Remove the gasket from the extension housing assembly.

Using a snap ring expander, remove the snap ring.

Remove the thrust needle roller bearing and 2 bearing races.

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

Using SST, tap out the oil seal.

SST

09308-00010

Install the transmission case on the overhaul attachment.

Remove the drain plug and 20 bolts.

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
   

Turn over the transmission.

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

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

Remove the ATF temperature sensor.

Remove the bolt and clamp.

Disconnect the 7 connectors from the shift solenoid valves.

Remove the bolt from the case.

Pull the transmission wire out of the transmission case.

Remove the O-ring from the transmission wire.

Remove the 19 bolts.

Remove the valve body assembly.

Remove the 3 transaxle case gaskets.

Remove the 3 brake drum gaskets.

Remove the check ball body and spring.

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

Remove the 2 O-rings from the piston.

NOTICE:

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

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

Remove the 2 O-rings from the piston.

NOTICE:

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

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

Remove the 2 O-rings from the piston.

Remove the C-1 accumulator valve and 2 springs.

Remove the 3 bolts and parking lock pawl bracket.

Disconnect the parking lock rod from the manual valve lever.

Pull out the parking lock pawl shaft from the front side, and 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 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 the manual valve lever shaft out through the case, and remove the manual valve lever.

Using a screwdriver, remove the 2 oil seals.

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

Using SST, remove the oil pump.

SST

09350-30020(09350-07020)

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

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

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

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

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

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

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

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

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.

Using SST, remove the snap ring.

SST

09350-30020(09350-07060)

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

Remove the 2nd brake cylinder from the case.

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

SST

09351-40010

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.

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

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

Standard free length:

15.72 mm (0.6189 in.)

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

Standard clearance:

0.2 to 0.60 mm (0.008 to 0.0236 in.)

Maximum clearance:

0.65 mm (0.0256 in.)

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

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

Maximum inside diameter:

57.48 mm (2.2630 in.)

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

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

Standard clearance:

0.2 to 0.60 mm (0.008 to 0.0236 in.)

Maximum clearance:

0.65 mm (0.0256 in.)

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

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

Maximum inside diameter:

57.48 mm (2.2630 in.)

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

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

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

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

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

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

Using a screwdriver, remove the snap ring.

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

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

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.

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

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

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

Standard free length:

17.05 mm (0.6712 in.)

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.

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

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

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

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.

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

Standard free length:

17.45 mm (0.6870 in.)

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.

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

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

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

Standard clearance:

0.12 to 0.68 mm (0.0047 to 0.0268 in.)

Maximum clearance:

0.73 mm (0.0287 in.)

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

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

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

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

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

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

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.

Using a caliper gauge, measure the inside diameter of the rear planetary ring gear bushing.

Maximum inside diameter:

32.18 mm (1.2669 in.)

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

Using a dial indicator, check the intermediate shaft runout.

Maximum runout:

0.08 mm (0.0031 in.)

NOTICE:

If the bend exceeds the specification, replace the intermediate shaft with a new one.

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

Standard diameter:

A:

25.96 to 25.98 mm (1.0220 to 1.0228 in.)

B:

25.96 to 25.98 mm (1.0220 to 1.0228 in.)

C:

32.06 to 32.08 mm (1.2622 to 1.2630 in.)

D:

32.06 to 32.08 mm (1.2622 to 1.2630 in.)

Minimum diameter:

A:

25.91 mm (1.0201 in.)

B:

25.91 mm (1.0201in.)

C:

32.01 mm (1.2602 in.)

D:

32.01 mm (1.2602 in.)

NOTICE:

If the outer diameter is outside the standard or less than the minimum, replace the intermediate shaft with the new one.

Remove the brake plate stopper spring from the case.

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

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.

Remove the rear planetary gear assembly from the case.

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

Remove the thrust needle roller bearing from the case.

Using a caliper gauge, measure the inside diameter of the rear planetary ring gear bushing.

Maximum inside diameter:

32.18 mm (1.2669 in.)

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

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

SST

09350-30020(09350-07050)

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

SST

09350-30020(09350-07070)

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

Standard free length:

23.74 mm (0.9346 in.)

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.

Remove the O-ring from No. 2 brake piston.

Using SST, remove the reaction sleeve.

SST

09350-30020(09350-07080)

Remove the O-ring from the reaction sleeve.

Using SST, remove the No. 4 brake piston.

SST

09350-30020(09350-07090)

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