Automatic Transmission Unit Disassembly

Remove the drain plug and gasket.

Remove the bolt and breather hose.

Remove the nut, washer and control shaft lever.

Using a screwdriver, bend the tabs of 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.

Detach the sensor connector clamp from the wire harness bracket.

Using a 19 mm union nut wrench, remove the sensor from the transmission assembly.

Remove the bolt and wire harness bracket.

Remove the O-ring from the sensor.

Remove the 2 tube unions.

Remove the 2 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.

Secure the transmission case to an overhaul attachment.

Remove the 8 bolts.

Remove the rear transfer adapter.

Using a screwdriver, pry out the oil seal.

NOTICE:

Do not damage the rear transfer adapter.

HINT:

Tape the screwdriver tip before use.

Using snap ring expander, remove the snap ring.

Remove the rear transfer case adaptor oil receiver from the rear transfer adaptor.

Using snap ring expander, remove the snap ring.

Remove the sensor rotor and key.

Remove the 19 bolts.

Insert the blade of an oil pan seal cutter between the transmission case and oil pan, and then cut through the applied sealer.

NOTICE:

Be careful not to damage the flanges of the oil pan and transmission case.

Remove the pan from the transmission case.

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 and valve body oil strainer from the valve body.

Remove the 3 gaskets from the oil strainer.

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 to remove it.

Remove the O-ring from the transmission wire connector.

Remove the 20 bolts and valve body.

Remove the check ball body and spring.

Apply compressed air (392 kPa (4.0 kgf/cm², 57 psi)) to the oil hole to remove the B-2 accumulator piston and spring.

NOTICE:

1. The application of compressed air may cause the piston to jump out. When removing the piston, hold it using a piece of cloth.
   
2. Take care not to splash ATF when applying the compressed air.
   

Remove the 2 O-rings from the piston.

Apply compressed air (392 kPa (4.0 kgf/cm², 57 psi)) to the oil hole to remove the C-2 accumulator piston and 2 springs.

NOTICE:

1. The application of compressed air may cause the piston to jump out. When removing the piston, hold it using a piece of cloth.
   
2. Take care not to splash ATF when applying the compressed air.
   

Remove the 2 O-rings from the piston.

Apply compressed air (392 kPa (4.0 kgf/cm², 57 psi)) to the oil hole to remove the B-0 accumulator piston and spring.

NOTICE:

1. The application of compressed air may cause the piston to jump out. When removing the piston, hold it using a piece of cloth.
   
2. Take care not to splash ATF when applying the compressed air.
   

Remove the 2 O-rings from the piston.

Apply compressed air (392 kPa (4.0 kgf/cm², 57 psi)) to the oil hole to remove the C-0 accumulator piston and 2 springs.

NOTICE:

1. The application of compressed air may cause the piston to jump out. When removing the piston, hold it using a piece of cloth.
   
2. Take care not to splash ATF when applying the compressed air.
   

Remove the O-ring from the piston.

Remove the 3 bolts and bracket.

Disconnect the parking lock rod from the manual valve lever to remove it.

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:

Tap out the spring pin slowly 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.

NOTICE:

Be careful not to damage the transmission case.

HINT:

Tape the screwdriver tip before use.

Stand the transmission upright.

Remove the 7 bolts from the transmission case.

Using SST, remove the oil pump.

SST

09610-20012

Remove the O-ring from the oil pump.

Remove the bearing race from the oil pump.

Remove the planetary gear together with the direct clutch and 1-way clutch from the transmission case.

Remove the bearing race and bearing.

Hold the overdrive direct clutch drum and turn the input shaft. Check that the input shaft can be turned clockwise freely and locks when turned counterclockwise.

Text in Illustration

	Lock
	Free

Using a screwdriver, pry out the snap ring from the overdrive direct clutch drum.

NOTICE:

Be careful not to damage the overdrive direct clutch drum.

HINT:

Tape the screwdriver tip before use.

Remove the flange, 2 discs and 2 plates.

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

NOTICE:

When assembling new discs, soak them in ATF for at least 15 minutes.

Place SST on the return spring and compress the return spring with a press.

SST

09350-30020(09350-07040)

Using SST, remove the snap ring.

SST

09350-30020(09350-07070)

Remove the clutch return spring.

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

Standard free length:

15.8 mm (0.622 in.)

Place the oil pump onto the torque converter, and then place the overdrive direct clutch onto the oil pump.

Hold the overdrive direct clutch piston by hand and apply compressed air (392 kPa (4.0 kgf/cm², 57 psi)) to the oil pump to remove the overdrive direct clutch piston.

HINT:

If the piston is at an angle and cannot be removed, press down on the protruding side and apply compressed air again.

Remove the 2 O-rings from the piston.

Check that the check ball is free by shaking the piston.

Check that the valve does not have leaks by applying low-pressure compressed air.
If the result is not as specified, replace the overdrive direct clutch piston sub-assembly.

Using a dial indicator, measure the inside diameter of the clutch drum bushes.

Standard inside diameter:

27.037 to 27.063 mm (1.0645 to 1.0654 in.)

Using a screwdriver, pry out the snap ring.

NOTICE:

Be careful not to damage the overdrive planetary gear assembly and the plate.

HINT:

Tape the screwdriver tip before use.

Remove the retaining plate.

Remove the overdrive 1-way clutch from the outer race.

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

Standard inside diameter:

11.200 to 11.221 mm (0.4409 to 0.4417 in.)

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

Standard clearance:

0.20 to 0.60 mm (0.00788 to 0.0236 in.)

Remove the ring gear together with the overdrive planetary ring gear flange from the transmission case.

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

Using a screwdriver, pry out the snap ring.

NOTICE:

Be careful not to damage the overdrive planetary ring gear and the flange.

HINT:

Tape the screwdriver tip before use.

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

Using a screwdriver, pry out the snap ring.

NOTICE:

Be careful not to damage the transmission case.

HINT:

Tape the screwdriver tip before use.

Remove the flange, 4 discs and 4 plates from the transmission case.

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

NOTICE:

When assembling new discs, soak them in ATF for at least 15 minutes.

Using a waterproof pen, place a mark on the second coast brake piston rod as shown in the illustration.

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

SST

09240-00020

Standard piston stroke:

1.5 to 3.0 mm (0.0591 to 0.118 in.)

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

Using SST, remove the snap ring.

SST

09350-30020(09350-07060)

Using SST, remove the overdrive brake assembly.

SST

09350-30020(09350-07020)

Remove the bearing and bearing race from the overdrive brake.

Remove the direct clutch together with the forward clutch from the case.

Remove the 2 bearings and bearing race.

Remove the forward clutch from the direct clutch.

Remove the thrust washer from the forward clutch.

Place the overdrive support assembly onto the direct clutch assembly.

Apply compressed air (392 kPa (4.0 kgf/cm², 57 psi)) into the oil passage and check that the overdrive brake piston moves smoothly.

Place SST on the return spring and compress the return spring with a press.

SST

09350-30020(09350-07030)

Using a screwdriver, pry out the snap ring.

NOTICE:

Be careful not to damage the overdrive support sub-assembly and return spring.

HINT:

Tape the screwdriver tip before use.

Remove the brake return spring.

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

Standard free length:

17.03 mm (0.671 in.)

Place the overdrive support onto the direct clutch assembly.

Hold the overdrive brake piston so that it is not slanted and apply compressed air (392 kPa (4 kgf/cm², 57 psi)) into the passage to remove the overdrive brake piston.

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

Remove the 2 oil seal rings from the overdrive support.

Remove the clutch drum thrust washer from the overdrive support.

Using SST, remove the snap ring.

SST

09350-30020(09350-07060)

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

Remove the 2 O-rings from the cover.

Firmly press the piston down to compress the compression spring.

Remove the E-ring.

Remove the piston rod, washer plate and spring from the piston.

Using a screwdriver, pry out the snap ring from the direct clutch drum.

NOTICE:

Be careful not to damage the direct clutch drum.

HINT:

Tape the screwdriver tip before use.

Remove the flange, 3 discs and 3 plates.

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

NOTICE:

When assembling new discs, soak them in ATF for at least 15 minutes.

Place SST on the spring retainer and compress the return spring with a press.

SST

09350-30020(09350-07040)

Using SST, remove the snap ring.

SST

09350-30020(09350-07070)

Remove the return spring.

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

Standard free length:

21.32 mm (0.839 in.)

Place the direct clutch drum on the overdrive support.

Hold the direct clutch piston and apply compressed air (196 kPa (2.0 kgf/cm², 28.5 psi)) to the overdrive support to remove the direct clutch piston.

HINT:

Make sure the direct clutch piston is not tilted before applying compressed air.

Using a small screwdriver, remove the 2 O-rings from the piston.

NOTICE:

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

HINT:

Tape the screwdriver tip before use.

Check that the check ball is free by shaking the piston.

Check that the valve does not have leaks by applying low-pressure compressed air.

Using a dial indicator, measure the inside diameter of the clutch drum bush.

Standard inside diameter:

53.915 to 53.94 mm (2.1227 to 2.1236 in.)

Place the overdrive support on wooden blocks or equivalent to prevent the forward clutch shaft from touching the work stand.

Place the forward clutch on the overdrive support.

Using a screwdriver, pry out the snap ring from the input shaft.

NOTICE:

Be careful not to damage the input shaft.

HINT:

Tape the screwdriver tip before use.

Remove the flange, 5 discs and 5 plates.

Remove the cushion plate.

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

NOTICE:

When assembling new discs, soak them in ATF for at least 15 minutes.

Place SST on the spring retainer and compress the return spring with a press.

SST

09350-30020(09350-07040)

Using SST, remove the snap ring.

SST

09350-30020(09350-07070)

Remove the return spring.

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

Standard free length:

19.47 mm (0.767 in.)

Place the input shaft onto the overdrive support.

Hold the forward clutch piston by hand and apply compressed air (196 kPa (2.0 kgf/cm², 28.5 psi)) to the overdrive support to remove the forward clutch piston.

Remove the O-ring from the input shaft.

NOTICE:

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

HINT:

Tape the screwdriver tip before use.

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

NOTICE:

Be careful not to damage the damage the forward clutch piston sub-assembly.

HINT:

Tape the screwdriver tip before use.

Check that the check ball is free by shaking the piston.

Check that the valve does not have leaks by applying low-pressure compressed air.

Remove the 3 oil seal rings from the input shaft.

Using a dial indicator, measure the inside diameter of the input shaft bush.

Standard inside diameter:

24.000 to 24.026 mm (0.9449 to 0.9459 in.)

Using a screwdriver, pry off the 2 E-rings from the pin and pull out the pin.

NOTICE:

Be careful not to damage the damage the transmission case.

HINT:

Tape the screwdriver tip before use.

Remove the second coast brake band from the case.

Remove the planetary ring gear from the case.

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

Place the output shaft on wooden blocks or equivalent.

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

Standard inside diameter:

24.000 to 24.026 mm (0.9449 to 0.9459 in.)

Remove the bearing race from the planetary gear.

Using SST, remove the snap ring.

SST

09350-30020(09350-07070)

Remove the planetary gear from the case.

Remove the bearing and bearing race from the planetary gear.

NOTICE:

Be careful not to damage the damage the front planetary gear assembly.

HINT:

Tape the screwdriver tip before use.

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

Standard clearance:

0.20 to 0.60 mm (0.00788 to 0.0236 in.)

Remove the sun gear together with the sun gear input drum and 1-way clutch from the case.

Hold the planetary sun gear and turn the 1-way clutch assembly. Check that the 1-way clutch hub can be turned clockwise freely and locks when turned counterclockwise.

Text in Illustration

	Lock
	Free

Remove the 2 oil seal rings from the sun gear input drum.

Place the planetary sun gear onto a wooden block or equivalent.

Using snap ring pliers, remove the snap ring.

Remove the input drum from the planetary sun gear.

Using a screwdriver, pry off the snap ring from the planetary sun gear.

NOTICE:

Be careful not to damage the damage the front planetary sun gear sub-assembly.

HINT:

Tape the screwdriver tip before use.

Using a dial indicator, measure the inside diameter of the planetary sun gear bushes.

Standard inside diameter:

27.000 to 27.026 mm (1.0630 to 1.0640 in.)

Using a screwdriver, remove the sleeve.

NOTICE:

Be careful not to damage the damage the transmission case.

HINT:

Tape the screwdriver tip before use.

Using a screwdriver, pry out the snap ring.

NOTICE:

Be careful not to damage the damage the transmission case and sleeve.

HINT:

Tape the screwdriver tip before use.

Remove the flange, 5 discs and 5 plates.

Using SST and a screwdriver, remove the snap ring.

SST

09350-30020(09350-07060)

Remove the output shaft together with the rear planetary gear, No. 2 1-way clutch, first and reverse brake disc set and second brake drum from the transmission case.

Remove the bearing from the transmission case.

Remove the second brake drum.

Check that the second brake piston moves smoothly when applying compressed air to and releasing low-pressure compressed air from the second brake drum.

Place SST on the spring retainer and compress the piston return spring with a press.

SST

09350-30020(09350-07040)

NOTICE:

Do not deform the spring seat. Stop compressing the spring when the spring seat is lowered to a position 1 to 2 mm (0.0394 to 0.0787 in.) from the snap ring groove.

Using SST, remove the snap ring.

SST

09350-30020(09350-07070)

Remove the second brake piston return spring seat.

Remove the piston return spring.

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

Standard free length:

16.05 mm (0.632 in.)

Hold the second brake piston by hand and apply compressed air to the second brake drum to remove the second brake piston.

HINT:

If the piston is at an angle and cannot be removed, press down on the protruding side and apply compressed air again.

Remove the 2 O-rings from the piston.

Remove the flange, 6 plates and 6 discs.

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

NOTICE:

When assembling new discs, soak them in ATF for at least 15 minutes.

Remove the rear planetary gear from the planetary ring gear.

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

Using a screwdriver, pry out the snap ring.

NOTICE:

Be careful not to damage the damage the rear planetary ring gear.

HINT:

Tape the screwdriver tip before use.

Remove the planetary ring gear flange.

Hold the planetary gear and turn the 1-way clutch inner race. Check that the 1-way clutch inner race can be turned counterclockwise freely and locks when turned clockwise.

Text in Illustration

	Lock
	Free

Remove the 1-way clutch inner race from the planetary gear.

Using a screwdriver, pry out the snap ring.

NOTICE:

Be careful not to damage the damage the rear planetary gear.

HINT:

Tape the screwdriver tip before use.

Remove the 1-way clutch from the rear planetary gear.

Remove the No. 2 planetary carrier thrust washer from the rear planetary gear.

Remove the No. 1 planetary carrier thrust washer from the rear planetary gear.

Using a feeler gauge, measure the thrust clearance.

Standard clearance:

0.20 to 0.60 mm (0.00788 to 0.0236 in.)

Place SST on the first 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)

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

Standard free length:

12.902 mm (0.508 in.)

Hold the No. 2 first and reverse brake piston and apply compressed air to 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 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.

Standard inside diameter:

38.113 to 38.138 mm (1.50051 to 1.50149 in.)