Automatic Transmission Unit (For 2Tr-Fe) Disassembly

Remove the breather plug hose from the automatic transmission case sub-assembly.

Remove the O-ring from the breather plug.

Remove the breather plug sub-assembly and breather plug from the breather plug hose.

Remove the bolt and transmission revolution sensor (NT) from the automatic transmission case sub-assembly.

Remove the O-ring from the transmission revolution sensor (NT).

Remove the bolt and transmission revolution sensor (SP2) from the automatic transmission case sub-assembly.

Remove the O-ring from the transmission revolution sensor (SP2).

Remove the nut, spring washer and transmission control shaft lever LH from the manual valve lever shaft.

Using a screwdriver, bend the tabs of the lock washer.

Remove the nut and the lock washer.

Remove the bolt and park/neutral position switch assembly from the automatic transmission case sub-assembly.

HINT:

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

Remove the refill plug from the transfer adapter sub-assembly.

Remove the O-ring from the refill plug.

Remove the 6 automatic transmission case plugs from the automatic transmission case sub-assembly.

Remove the 6 O-rings from the 6 automatic transmission case plugs.

Using a T55 "TORX" socket wrench, remove the automatic transmission case plug from the automatic transmission case sub-assembly.

Remove the O-ring from the automatic transmission case plug.

Remove the 2 oil cooler tube unions from the automatic transmission case sub-assembly.

Remove the 2 O-rings from the 2 oil cooler tube unions.

Remove the 10 bolts and transfer adapter sub-assembly from the automatic transmission case sub-assembly.

HINT:

Use a brass bar and hammer to remove the transfer adapter sub-assembly.

Remove the 2 straight pins from the transfer adapter sub-assembly.

HINT:

It is not necessary to remove the straight pins they are being replaced.

Using a screwdriver, pry out the transfer adapter oil seal from the transfer adapter sub-assembly.

NOTICE:

Be careful not to damage the transfer adapter sub-assembly.

HINT:

Tape the screwdriver tip before use.

Using snap ring pliers, remove the snap ring and rear transfer case adapter oil receiver from the transfer adapter sub-assembly.

Remove the 12 bolts and automatic transmission housing from the automatic transmission case sub-assembly.

Install the automatic transmission case sub-assembly to an overhaul attachment.

Using a 5 mm socket hexagon wrench, remove the overflow plug and gasket.

Remove the drain plug and gasket.

Remove the 10 bolts, automatic transmission oil pan sub-assembly and automatic transmission oil pan gasket.

Remove the 4 transmission oil cleaner magnets from the automatic transmission oil pan sub-assembly.

Examine the particles in the automatic transmission oil pan sub-assembly.

1. Collect any steel chips with the removed transmission oil cleaner magnets. Carefully inspect the foreign matter and particles in the automatic transmission oil pan sub-assembly and on the transmission oil cleaner magnets to anticipate the type of wear you will find in the automatic transmission assembly.
   Steel (magnetic): bearing, gear and clutch plate wear
   Brass (non-magnetic): bush wear
   

Remove the 2 bolts and 2 temperature sensor clamps, and disconnect the 2 temperature sensors.

Disconnect the 7 solenoid valve connectors and transmission wire from the transmission valve body assembly.

Remove the bolt and pull out the transmission wire from the automatic transmission case sub-assembly.

Remove the O-ring from the connector of transmission wire.

Remove the 2 O-rings from the 2 temperature sensors.

Remove the 3 bolts and valve body oil strainer assembly from the transmission valve body assembly.

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

Remove the bolt, detent spring cover and detent spring from the transmission valve body assembly.

Remove the 12 bolts and transmission valve body assembly from the automatic transmission case sub-assembly.

Remove the 2 transmission case gaskets from the automatic transmission case sub-assembly.

Remove the 2 brake drum gaskets from the automatic transmission case sub-assembly.

Remove the 3 bolts and parking lock pawl bracket from the automatic transmission case sub-assembly.

Remove the parking lock rod sub-assembly from the manual valve lever sub-assembly.

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

Remove the E-ring from the parking lock pawl shaft.

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

NOTICE:

Be careful not to damage the manual valve lever shaft.

HINT:

Tape the screwdriver tip before use.

Using a 3 mm pin punch and hammer, drive out the spring pin.

HINT:

Slowly drive out the spring pin so that it does not fall into the automatic transmission case sub-assembly.

Pull the manual valve lever shaft out through the case and remove the manual valve lever sub-assembly.

Using a screwdriver, pry out the 2 manual valve lever shaft oil seals from the automatic transmission case sub-assembly.

NOTICE:

Be careful not to damage the automatic transmission case sub-assembly.

HINT:

Tape the screwdriver tip before use.

Remove the 10 bolts.

Using SST, pull out the oil pump assembly from the automatic transmission case sub-assembly.

SST

09610-20012

Remove the 2 thrust bearing races from the oil pump assembly.

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

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

Remove the 3 thrust needle roller bearings from the clutch drum and input shaft assembly.

Remove the direct clutch drum sub-assembly from the input shaft sub-assembly.

Using a dial indicator, measure the clearance of the No. 1 clutch at several points while applying compressed air (196 kPa, 2.0 kgf/cm², 28 psi) to the oil hole as shown in the illustration, and calculate the average.

Standard clearance:

0.75 to 1.05 mm (0.0296 to 0.0413 in.)

HINT:

There are forward clutch flanges of different thicknesses.

Forward Clutch Flange Thickness:

Part No.	Thickness (mm (in.))
35635-71010	3.0 (0.118)
35635-71020	3.1 (0.122)
35635-71030	3.2 (0.126)
35635-71040	3.3 (0.130)
35635-71050	3.4 (0.134)
35635-71060	3.5 (0.138)
35635-71070	3.6 (0.142)
35635-71080	3.7 (0.146)
35635-71090	3.8 (0.150)
35635-71100	3.9 (0.154)
35635-71110	4.0 (0.157)
35635-71120	4.1 (0.161)
35635-71130	4.2 (0.165)

Remove the 3 clutch drum oil seal rings from the input shaft sub-assembly.

Secure the input shaft sub-assembly in a vise between aluminum plates.

NOTICE:

Do not overtighten the vise.

Using a screwdriver, remove the snap ring.

NOTICE:

Be careful not to damage the input shaft sub-assembly.

HINT:

Tape the screwdriver tip before use.

Remove the forward clutch flange, 5 No. 1 clutch discs and 5 No. 1 clutch plates from the input shaft sub-assembly.

Check if the contact surfaces of the No. 1 clutch discs, No. 1 clutch plates and No. 1 clutch flange are worn or burnt.
If necessary, replace them.

NOTICE:

1. If the lining of any No. 1 clutch disc is peeled or discolored, or even if part of a groove is damaged, replace all the No. 1 clutch discs.
   
2. Before installing new No. 1 clutch discs, soak them in ATF for at least 15 minutes.
   

Place SST on the No. 1 clutch balancer, and compress the forward clutch return spring sub-assembly with a press.

SST

09387-00110

Using SST, remove the snap ring.

SST

09350-30020(09350-07070)

Remove the No. 1 clutch balancer and forward clutch return spring sub-assembly from the input shaft sub-assembly.

Remove the O-ring from the No. 1 clutch balancer.

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

Standard free length:

26.74 mm (1.053 in.)

While holding the forward clutch piston, apply compressed air to the oil hole of the input shaft sub-assembly to remove the forward clutch piston from the input shaft sub-assembly.

Remove the O-ring from the forward clutch piston.

Remove the O-ring from the input shaft sub-assembly.

Using a caliper gauge, measure the inside diameter of the input shaft sub-assembly bushing.

Standard inside diameter:

20.000 to 20.025 mm (0.7874 to 0.7883 in.)

Using a dial indicator, measure the clearance of the No. 2 clutch at several points while applying compressed air (196 kPa, 2.0 kgf/cm², 28 psi) to the oil hole as shown in the illustration, and calculate the average.

Standard clearance:

0.4 to 0.7 mm (0.0158 to 0.0275 in.)

HINT:

There are direct clutch flanges of different thicknesses.

Direct Clutch Flange Thickness:

Part No.	Thickness (mm (in.))
35675-71010	3.0 (0.118)
35675-71020	3.1 (0.122)
35675-71030	3.2 (0.126)
35675-71040	3.3 (0.130)
35675-71050	3.4 (0.134)
35675-71060	3.5 (0.138)
35675-71070	3.6 (0.142)
35675-71080	3.7 (0.146)
35675-71090	3.8 (0.150)

Using a screwdriver, remove the snap ring from the direct clutch drum sub-assembly.

NOTICE:

Be careful not to damage the direct clutch drum sub-assembly.

HINT:

Tape the screwdriver tip before use.

Remove the direct clutch flange, 4 No. 2 clutch discs and 4 No. 2 clutch plates from the direct clutch drum sub-assembly.

Check if the contact surfaces of the No. 2 clutch discs, No. 2 clutch plates and No. 2 clutch flange are worn or burnt.
If necessary, replace them.

NOTICE:

1. If the lining of any No. 2 clutch disc is peeled or discolored, or even if part of a groove is damaged, replace all the No. 2 clutch discs.
   
2. Before installing new No. 2 clutch discs, soak them in ATF for at least 15 minutes.
   

Place SST on the No. 2 clutch balancer, and compress the direct clutch return spring sub-assembly with a press.

SST

09380-60011(09381-06030,09381-06040,09381-06080,09381-06100,09381-06110)

Using SST, remove the snap ring.

SST

09350-30020(09350-07070)

Remove the No. 2 clutch balancer and direct clutch return spring sub-assembly from the direct clutch drum sub-assembly.

Remove the O-ring from the No. 2 clutch balancer.

Using a vernier caliper, measure the free length of the direct clutch return spring sub-assembly including the spring seat.

Standard free length:

22.14 mm (0.872 in.)

Place the oil pump assembly onto the torque converter assembly, and then place the direct clutch drum sub-assembly onto the oil pump assembly.

While holding the direct clutch piston, apply compressed air to the oil hole of the oil pump assembly to remove the direct clutch piston from the direct clutch drum sub-assembly.

Remove the 2 O-rings from the direct clutch piston.

Using a caliper gauge, measure the inside diameter of the direct clutch drum sub-assembly bushing.

Standard inside diameter:

59.515 to 59.540 mm (2.3432 to 2.3440 in.)

Remove the multiple disc clutch hub from the automatic transmission case sub-assembly.

Remove the 2 thrust bearing races from the multiple disc clutch hub.

Remove the forward clutch hub sub-assembly from the automatic transmission case sub-assembly.

Remove the 2 thrust needle roller bearings from the forward clutch hub sub-assembly.

Using a caliper gauge, measure the inside diameter of the forward clutch hub sub-assembly bushing.

Standard inside diameter:

26.037 to 26.062 mm (1.0251 to 1.0260 in.)

Remove the sun gear input drum sub-assembly from the automatic transmission case sub-assembly.

Remove the thrust needle roller bearing and thrust bearing race from the sun gear input drum sub-assembly.

Using a caliper gauge, measure the inside diameter of the sun gear input drum sub-assembly bushing.

Standard inside diameter:

35.811 to 35.835 mm (1.4099 to 1.4108 in.)

Remove the front planetary gear assembly from the automatic transmission case sub-assembly.

Remove the 2 thrust bearing races from the front planetary gear assembly

Using a caliper gauge, measure the inside diameter of the front planetary gear assembly bushing.

Standard inside diameter:

35.811 to 35.835 mm (1.4099 to 1.4108 in.)

Remove the front planetary ring gear with front planetary ring gear flange sub-assembly from the automatic transmission case sub-assembly.

Remove the thrust needle roller bearing and thrust bearing race from the front planetary ring gear with front planetary ring gear flange sub-assembly.

Using needle-nose pliers, remove the snap ring and front planetary ring gear flange sub-assembly from the front planetary ring gear.

Using a caliper gauge, measure the inside diameter of the front planetary ring gear flange sub-assembly bushing.

Standard inside diameter:

54.038 to 54.063 mm (2.1275 to 2.1284 in.)

Make sure that the No. 2 brake piston moves smoothly when applying and releasing compressed air (392 kPa, 4.0 kgf/cm², 57 psi).

Using a feeler gauge, measure the No. 2 brake pack clearance between the No. 2 brake disc and No. 2 brake flange.

Standard clearance:

0.4 to 0.7 mm (0.0158 to 0.0275 in.)

No. 2 Brake Flange Thickness:

Mark	Thickness (mm (in.))
0	2.0 (0.0787)
1	2.1 (0.0827)
2	2.2 (0.0866)
3	2.3 (0.0906)
4	2.4 (0.0945)
5	2.5 (0.0984)
6	2.6 (0.102)
7	2.7 (0.106)
8	2.8 (0.110)

Place SST on the No. 2 brake cylinder, and compress the No. 2 brake piston return spring sub-assembly with a press.

SST

09380-60011(09381-06010,09381-06020,09381-06040,09381-06050,09381-06060,09381-06090,09381-06100,09381-06110,09381-06120)

Using a screwdriver, remove the snap ring from the automatic transmission case sub-assembly.

NOTICE:

Be careful not to damage the automatic transmission case sub-assembly.

HINT:

Tape the screwdriver tip before use.

Remove the No. 2 brake cylinder with No. 2 brake piston and No. 2 brake piston return spring sub-assembly from the automatic transmission case sub-assembly.

Using a vernier caliper, measure the free length of the No. 2 brake piston return spring sub-assembly including the spring seat.

Standard free length:

16.68 mm (0.657 in.)

While holding the No. 2 brake piston, apply compressed air to the oil hole of the No. 2 brake cylinder to remove the No. 2 brake piston from the No. 2 brake cylinder.

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

Remove the 2 No. 2 brake flanges, 4 No. 2 brake discs and 3 No. 2 brake plates from the automatic transmission case sub-assembly.

Check if the contact surfaces of the No. 2 brake discs, No. 2 brake plates and No. 2 brake flanges are worn or burnt.
If necessary, replace them.

NOTICE:

1. If the lining of any No. 2 brake disc is peeled or discolored, or even if part of a groove is damaged, replace all the No. 2 brake discs.
   
2. Before installing new No. 2 brake discs, soak them in ATF for at least 15 minutes.
   

Remove the center planetary ring gear flange with center planetary ring gear from the automatic transmission case sub-assembly.

Remove the 2 thrust needle roller bearings from the center planetary ring gear flange with center planetary ring gear.

Using a screwdriver, remove the snap ring from the center planetary ring gear flange with center planetary ring gear.

NOTICE:

Be careful not to damage the center planetary ring gear flange with center planetary ring gear.

HINT:

Tape the screwdriver tip before use.

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

Remove the center planetary gear assembly from the automatic transmission case sub-assembly.

Remove the thrust bearing race from the center planetary gear assembly.

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

Standard clearance:

0.12 to 0.68 mm (0.00473 to 0.0267 in.)

Remove the planetary sun gear from the automatic transmission case sub-assembly.

Make sure that the No. 1 brake piston moves smoothly when applying and releasing compressed air (392 kPa, 4.0 kgf/cm², 57 psi).

Using a feeler gauge, measure the No. 1 brake pack clearance between the No. 1 brake disc and No. 1 brake flange.

Standard clearance:

0.3 to 0.6 mm (0.0119 to 0.0236 in.)

No. 1 Brake Flange Thickness:

Mark	Thickness (mm (in.))
0	4.9 (0.193)
1	5.0 (0.197)
2	5.1 (0.201)
3	5.2 (0.205)
4	5.3 (0.209)
5	5.4 (0.213)
6	5.5 (0.217)
7	5.6 (0.220)
8	5.7 (0.224)
A	5.8 (0.228)

Using a screwdriver, remove the snap ring from the automatic transmission case sub-assembly.

NOTICE:

Be careful not to damage the automatic transmission case sub-assembly.

HINT:

Tape the screwdriver tip before use.

Remove the No. 1 brake flange, 3 No. 1 brake discs and 3 No. 1 brake plates from the automatic transmission case sub-assembly.

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

NOTICE:

1. If the lining of any No. 1 brake disc is peeled or discolored, or even if part of a groove is damaged, replace all the No. 1 brake discs.
   
2. Before installing new No. 1 brake discs, soak them in ATF for at least 15 minutes.
   

Place SST on the No. 1 brake piston return spring sub-assembly, and compress the No. 1 brake piston return spring sub-assembly with a press.

SST

09380-60011(09381-06010,09381-06040,09381-06050,09381-06070,09381-06090,09381-06100,09381-06110,09381-06120)

Using a screwdriver, remove the snap ring from the automatic transmission case sub-assembly.

NOTICE:

Be careful not to damage the automatic transmission case sub-assembly.

HINT:

Tape the screwdriver tip before use.

Remove the No. 1 brake piston return spring sub-assembly and No. 1 brake cylinder with No. 1 brake piston from the automatic transmission case sub-assembly.

Using a vernier caliper, measure the free length of the No. 1 brake piston return spring sub-assembly including the spring seat.

Standard free length:

16.72 mm (0.658 in.)

While holding the No. 1 brake piston, apply compressed air to the oil hole of the No. 1 brake cylinder to remove the No. 1 brake piston from the No. 1 brake cylinder.

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

Make sure that the 1st and reverse brake piston moves smoothly when applying and releasing compressed air (392 kPa, 4.0 kgf/cm², 57 psi).

Using a feeler gauge, measure the No. 4 brake pack clearance between the No. 4 brake disc and No. 4 brake flange.

Standard clearance:

0.5 to 0.8 mm (0.0197 to 0.0314 in.)

No. 4 Brake Flange Thickness:

Mark	Thickness (mm (in.))
0	1.80 (0.0709)
1	1.97 (0.0776)
3	2.11 (0.0831)
4	2.25 (0.0886)
5	2.39 (0.0941)
7	2.53 (0.0996)
8	2.67 (0.105)
10	2.81 (0.111)
11	2.95 (0.116)
12	3.09 (0.122)
14	3.23 (0.127)

Using SST, remove the snap ring from the automatic transmission case sub-assembly.

SST

09350-30020(09350-07060)

Remove the intermediate shaft with No. 3 one-way clutch assembly and rear planetary ring gear from the automatic transmission case sub-assembly.

Hold the rear planetary ring gear and turn the No. 3 one-way clutch assembly.

Text in Illustration

	Lock
	Free

Check that the No. 3 one-way clutch assembly turns freely when turned counterclockwise and locks when turned clockwise.
If there is a problem with the No. 3 one-way clutch assembly, replace it.

Remove the No. 3 one-way clutch assembly with one-way clutch inner race from the intermediate shaft with rear planetary ring gear.

Remove the one-way clutch inner race from the No. 3 one-way clutch assembly.

Remove the rear planetary ring gear flange sub-assembly with rear planetary ring gear from the intermediate shaft.

Remove the thrust bearing race from the rear planetary ring gear flange sub-assembly with rear planetary ring gear.

Remove the thrust needle roller bearing and thrust bearing race from the intermediate shaft.

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

Standard inside diameter:

32.176 to 32.201 mm (1.2668 to 1.2677 in.)

Using a dial indicator, check the intermediate shaft runout.

Standard runout:

0.03 mm (0.00118 in.)

Using a micrometer, check the outer diameter of the intermediate shaft at each point shown in the illustration.

Standard diameter:

A:

32.062 to 32.075 mm (1.2623 to 1.2627 in.)

B:

25.962 to 25.975 mm (1.0222 to 1.0226 in.)

C:

19.963 to 19.976 mm (0.7860 to 0.7864 in.)

Using a screwdriver, remove the snap ring from the rear planetary ring gear flange sub-assembly with rear planetary ring gear.

NOTICE:

Be careful not to damage the rear planetary ring gear flange sub-assembly with rear planetary ring gear.

HINT:

Tape the screwdriver tip before use.

Remove the rear planetary ring gear from the rear planetary ring gear flange sub-assembly.

Remove the rear planetary gear assembly with No. 4 brake disc from the automatic transmission case sub-assembly.

Remove the 2 thrust needle roller bearings and thrust bearing race from the rear planetary gear assembly with No. 4 brake disc.

Remove the thrust bearing race from the automatic transmission case sub-assembly.

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

Standard clearance:

0.2 to 0.6 mm (0.00788 to 0.0236 in.)

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

Standard inside diameter:

20.000 to 20.025 mm (0.7874 to 0.7883 in.)

Remove the No. 4 brake flange, 5 No. 4 brake discs and 4 No. 4 brake plates from the rear planetary gear assembly.

Remove the No. 4 brake flange from the automatic transmission case sub-assembly.

Check if the contact surfaces of the No. 4 brake discs, No. 4 brake plates and No. 4 brake flanges are worn or burnt.
If necessary, replace them.

NOTICE:

1. If the lining of any No. 4 brake disc is peeled or discolored, or even if part of a groove is damaged, replace all the No. 4 brake discs.
   
2. Before installing new No. 4 brake discs, soak them in ATF for at least 15 minutes.
   

Place SST on the 1st and reverse brake return spring sub-assembly and compress the 1st and reverse brake return spring sub-assembly.

SST

09380-60011(09381-05040,09381-05050,09381-06030,09381-06040,09381-06080,09381-06120,09381-06130,09381-06140)

Using SST, remove the snap ring from the automatic transmission case sub-assembly.

SST

09350-30020(09350-07070)

Remove the 1st and reverse brake return spring sub-assembly from the automatic transmission case sub-assembly.

Apply compressed air to the oil hole of the automatic transmission case sub-assembly to remove the 1st and reverse brake piston from the automatic transmission case sub-assembly.

Remove the O-ring from the 1st and reverse brake piston.

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

Standard free length:

23.74 mm (0.935 in.)

Using SST, remove the brake reaction sleeve from the automatic transmission case sub-assembly.

SST

09350-30020(09350-07080)

Remove the 2 O-rings from the brake reaction sleeve.

Using SST, remove the No. 4 brake piston from the automatic transmission case sub-assembly.

SST

09350-30020(09350-07090)

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

Remove the 2 brake plate stopper springs from the automatic transmission case sub-assembly.