Automatic Transmission Unit Disassembly

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

Using a screwdriver, bend the tabs of 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 2 O-rings from the oil cooler tube unions.

Remove the 2 bolts and 2 speed sensors.

Remove the 2 O-rings from the sensors.

Remove the 3 bolts.

Remove the breather tube.

Remove the O-ring from the tube.

Remove the 10 bolts.

Remove the transmission housing.

Remove the 8 bolts.

Remove the transmission case adapter.

HINT:

Use a brass bar and a hammer to remove the transmission case adapter.

Remove the 2 transfer case ring pins from the transmission case adapter.

Using a screwdriver, pry out the oil seal.

HINT:

Wrap the tip of the screwdriver with tape.

NOTICE:

Be careful not to damage the transmission case.

Using snap ring pliers, remove the snap ring and oil receiver.

Install the transmission case to an 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): bushing wear
   

Turn over the transmission.

Remove the 4 bolts and oil strainer from the valve body.

Remove the O-ring from the oil strainer.

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

Disconnect the 7 connectors from the 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 bolt, detent spring cover and detent spring.

Remove the 19 bolts and valve body.

Remove the 3 gaskets.

Remove the 3 gaskets.

Remove the check ball body and spring.

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

Remove the 2 O-rings from the piston.

NOTICE:

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

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

Remove the 2 O-rings from the piston.

NOTICE:

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

Apply compressed air to the oil hole to remove the C-3 accumulator piston and 2 springs.

Remove the 2 O-rings from the piston.

Remove the C-1 accumulator valve and 2 springs.

Remove the 3 bolts and 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, pry out the 2 oil seals.

HINT:

Wrap the tip of the screwdriver with tape.

NOTICE:

Be careful not to damage the transmission case.

Remove the 10 bolts.

Using SST, remove the oil pump.

SST

09350-30020(09350-07020)

Remove the O-ring from the front oil pump.

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

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

Remove the clutch drum thrust washer and 2 thrust needle roller bearings.

Hold the reverse clutch hub and turn the 1-way clutch assembly.

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

Text in Illustration

	Lock
	Free

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

Place the oil pump onto the torque converter, and then place the clutch drum and input shaft assembly onto the oil pump.

Using a screwdriver, remove the snap ring.

Remove the reverse clutch hub sub-assembly, reverse clutch reaction sleeve, clutch cushion, plate reverse clutch flange, 5 reverse clutch discs and 4 clutch plates from the clutch drum.

Remove the reverse clutch reaction sleeve from the reverse clutch hub.

Remove the clutch cushion plate, reverse clutch flange, 5 discs and 4 plates from the reverse clutch hub.

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) the 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 dial indicator, measure the inside diameter of the reverse clutch hub bush.

Standard inside diameter:

35.812 to 35.837 mm (1.410 to 1.411 in.)

Maximum inside diameter:

35.887 mm (1.413 in.)

1. If the inside diameter is more than the maximum, replace the reverse clutch hub.
   

Remove the forward clutch hub from the clutch drum.

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

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

Standard inside diameter:

26.037 to 26.062 mm (1.025 to 1.026 in.)

Maximum inside diameter:

26.112 mm (1.028 in.)

1. If the inside diameter is more than the maximum, replace the forward clutch hub.
   

Remove the multiple disc clutch hub from the clutch drum.

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

Remove the thrust needle roller bearing from the clutch drum.

Remove the input shaft assembly from the clutch drum.

Remove the 3 oil seal rings from the input shaft.

Using a screwdriver, remove the hole snap ring.

for 1GR-FE:
Remove the 2 flanges, 6 discs and 5 plates from the input shaft.

for 1KD-FTV:
Remove the 2 flanges, 7 discs and 6 plates from the input shaft.

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) the 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.

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

SST

09350-30020(09350-07040,09350-07070)

Using a snap ring expander, remove the snap ring.

Remove the clutch balancer and forward clutch return spring from the input shaft assembly.

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

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

Standard free length:

26.74 mm (1.05 in.)

Hold the input shaft by hand and apply compressed air (392 kPa (4.0 kgf/cm², 57 psi)) to the input shaft to remove the forward clutch piston.

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

Remove the reverse clutch flange from the clutch drum.

Using a screwdriver, remove the 2 hole snap rings from the clutch drum.

for 1GR-FE:
Remove the reverse clutch flange, 5 discs and 5 plates from the clutch drum.

for 1KD-FTV:
Remove the reverse clutch flange, 6 discs and 6 plates from the clutch drum.

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) the 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.

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

SST

09387-00070

Using SST, remove the snap ring.

SST

09350-30020(09350-07070)

Remove the reverse clutch return spring and O-ring from the reverse clutch piston.

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

Standard free length:

21.04 mm (0.828 in.)

Remove the reverse clutch piston sub-assembly from the clutch drum.

Remove the O-ring from the reverse clutch piston.

Remove the O-ring from the clutch drum.

Place SST on the direct clutch piston, and compress the return spring with a press.

SST

09320-89010

Using SST, remove the snap ring.

SST

09350-30020(09350-07070)

Using 2 screwdrivers, remove the direct clutch piston sub-assembly from the clutch drum.

Remove the O-ring from the clutch drum.

Remove the No. 2 clutch balancer and direct clutch return spring from the direct clutch piston.

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

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

Standard free length:

19.51 mm (0.768 in.)

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

Remove the flange, 4 discs, 4 plates and cushion plate 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) the 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 No. 1 planetary carrier thrust washer from the case.

Remove the 2nd brake cylinder from the case.

Using SST and a press, compress the return spring and remove the snap ring.

SST

09351-40010

Hold the 2nd brake cylinder and apply compressed air (392 kPa (4.0 kgf/cm², 57 psi)) to the 2nd 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 (0.619 in.)

Remove the front planetary gear assembly and 1-way clutch inner race from the case.

Remove the No. 5 thrust bearing race, thrust needle roller bearing and No. 2 planetary carrier thrust washer from the front planetary gear assembly.

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

Standard clearance:

0.2 to 0.6 mm (0.00787 to 0.0236 in.)

Maximum clearance:

0.65 mm (0.0256 in.)

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

Using a cylinder gauge, measure the inside diameter of the front planetary gear bush.

Maximum inside diameter:

57.48 mm (2.26 in.)

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

Install the 1-way clutch 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 turns freely counterclockwise and locks when turned clockwise.

Text in Illustration

	Lock
	Free

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

Remove the front planetary ring gear and thrust needle roller 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 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:

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 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 (0.671 in.)

Hold the No. 1 brake cylinder and apply compressed air (392 kPa (4.0 kgf/cm², 57 psi)) to No. 1 brake cylinder 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, 3 discs, 3 plates and brake piston return spring from the 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:

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 (0.687 in.)

Apply compressed air (392 kPa (4.0 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 No. 6 thrust bearing race, center planetary gear and planetary sun gear from the case.

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

Standard clearance:

0.12 to 0.68 mm (0.00472 to 0.0268 in.)

Maximum clearance:

0.73 mm (0.0287 in.)

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

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

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

Hold the rear planetary ring gear flange and turn the 1-way clutch. Check that the 1-way clutch turns freely counterclockwise and locks when turned clockwise.

Text in Illustration

	Lock
	Free

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

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

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

Standard inside diameter:

32.176 to 32.201 (1.267 to 1.268 in.)

Maximum inside diameter:

32.251 mm (1.270 in.)

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

Using a dial indicator, measure the intermediate shaft runout.

Standard runout:

0.03 mm (0.00118 in.)

Maximum runout:

0.08 mm (0.00315 in.)

Using a micrometer, measure the diameter of the intermediate shaft at the positions shown in the diagram.

Standard diameter:

A, B:

25.962 to 25.975 mm (1.022 to 1.023 in.)

C, D:

32.062 to 32.075 mm (1.262 to 1.263 in.)

Minimum diameter:

A, B:

25.912 mm (1.02 in.)

C, D:

32.012 mm (1.26 in.)

Remove the 7 plates, 8 discs and 2 flanges from the 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:

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

Remove the rear planetary gear assembly from the case.

Remove the 2 thrust needle roller bearings from the rear planetary gear.

Remove the No. 9 thrust bearing race from the case.

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

Standard clearance:

0.2 to 0.6 mm (0.00787 to 0.0236 in.)

Maximum clearance:

0.65 mm (0.0256 in.)

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

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

Maximum inside diameter:

20.075 mm (0.790 in.)

1. If the inside diameter is more than the maximum, replace the rear planetary gear assembly.
   

Place SST on the spring retainer 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:

23.74 mm (0.935 in.)

Apply compressed air (392 kPa (4.0 kgf/cm², 57 psi)) to the transmission case to remove the 1st and reverse 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 1st and reverse brake piston.

Using SST, remove the reaction sleeve.

SST

09350-30020(09350-07080)

Remove the 2 O-rings from the reaction sleeve.

Using SST, remove the brake piston.

SST

09350-30020(09350-07090)

Remove the 2 O-rings from the brake piston.