Automatic Transmission Unit Disassembly

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

Remove the clamp from the breather plug hose.

Remove the No. 1 breather plug and No. 2 breather plug from the breather plug hose.

Remove the breather plug O-ring from the No. 1 breather plug.

Remove the 16 bolts and automatic transmission housing from the automatic transmission case sub-assembly.

Install the automatic transmission assembly to an overhaul attachment.

Remove the 10 bolts.

Remove the rear transfer adapter.

HINT:

Tap on the circumference of the rear transfer adapter with a plastic-faced hammer to remove the rear transfer adapter.

Remove the O-ring from the rear transfer adapter.

Using a screwdriver, pry out the transfer case adapter rear oil seal.

NOTICE:

Be careful not to damage the rear transfer adapter.

HINT:

Tape the screwdriver tip before use.

Disconnect the switch connector.

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

Remove the bush from the transmission control shaft lever.

Remove the No. 1 floor shift bush from the transmission control shaft lever.

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

HINT:

Tape the screwdriver tip before use.

Remove the lock nut and lock washer.

Remove the 2 bolts and park/neutral position switch 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 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 refill plug from the automatic transmission case sub-assembly.

Remove the O-ring from the refill plug.

for T55H "TORX" Type:

1. Using a T55H "TORX" socket wrench, remove the 2 automatic transmission case plugs from the automatic transmission case sub-assembly.
   

   Text in Illustration

   *A	for LH Side
   *B	for Rear Side

2. Remove the 2 O-rings from the 2 automatic transmission case plugs.
   

for 17 mm Hexagon Type:

1. Remove the automatic transmission case plug from the automatic transmission case sub-assembly.
   

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

Remove the 11 bolts, automatic transmission oil pan sub-assembly and automatic transmission oil pan gasket.

NOTICE:

Some fluid will remain in the automatic transmission oil pan sub-assembly. Remove all the pan bolts, and carefully remove the automatic transmission oil pan sub-assembly.

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 look at the foreign objects and particles in the automatic transmission oil pan sub-assembly and on the transmission oil cleaner magnets to guess the type of wear which might be found in the transmission.
   Result:
   Steel (magnetic): bearing, gear and clutch plate wear
   Brass (non-magnetic): bush wear
   

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

NOTICE:

Be careful as some fluid will come out of the valve body oil strainer assembly.

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

Remove the bolt, lock plate and ATF temperature sensor.

Using a screwdriver, disconnect the transmission revolution sensor (NT) connector.

HINT:

Tape the screwdriver tip before use.

Disconnect the 9 connectors from the solenoid valves.

Remove the 14 bolts and transmission valve body assembly.

Disconnect the connector from the transmission revolution sensor (SP2).

Remove the bolt and wire harness clamp.

Disconnect the transmission wire connector.

HINT:

Detach the claw, pull the lever, and then disconnect the transmission wire connector.

Remove the bolt and pull out the transmission wire.

Remove the bolt and wire harness clamp.

Disconnect the connector from the transmission revolution sensor (SP2).

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

Remove the 3 bolts and parking lock pawl bracket.

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

NOTICE:

Be careful not to damage the manual valve lever sub-assembly.

HINT:

Tape the screwdriver tip before use.

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

HINT:

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

Remove the manual valve lever shaft and manual valve lever sub-assembly from the automatic transmission case sub-assembly.

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

Remove the parking lock pawl shaft, parking lock pawl and spring.

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

Using a screwdriver, pry out the 2 manual valve lever shaft oil seals.

NOTICE:

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

HINT:

Tape the screwdriver tip before use.

Remove the bolt, manual detent spring sub-assembly and manual detent spring cover.

Remove the 11 bolts from the oil pump assembly.

Pull out the oil pump assembly from the automatic transmission case sub-assembly.

NOTICE:

Do not damage the oil pump assembly.

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

Remove the overdrive brake plate stopper spring from the automatic transmission case sub-assembly.

Remove the overdrive and reverse multiple disc clutch assembly and front planetary gear assembly with No. 1 brake disc set from the automatic transmission case sub-assembly.

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

Remove the snap ring from the automatic transmission case sub-assembly.

Remove the 6 No. 1 brake plates, 6 No. 1 brake discs and No. 1 brake flange.

Check whether the sliding surfaces of the No. 1 brake discs, No. 1 brake plates and the No. 1 brake flange are worn or burnt.

NOTICE:

1. If the linings of the No. 1 brake discs are peeled off or discolored, or if any part of the printed numbers is damaged, replace all the No. 1 brake discs.
   
2. Before assembling new No. 1 brake discs, soak them in ATF for at least 2 hours.
   

Remove the front planetary gear assembly together with the planetary sun gear from the overdrive and reverse multiple disc clutch assembly.

Remove the front planetary sun gear from the front planetary gear assembly.

Remove the planetary carrier thrust washer from the front planetary gear assembly.

Remove the 3 oil seal rings from the front planetary gear assembly.

Remove the 2 oil seal rings from the front planetary gear assembly.

Remove the front planetary gear radial needle roller bearing from the front planetary gear assembly.

Using a feeler gauge, measure the clearance between the front planetary gear assembly and each pinion gear.

Standard Clearance:

0.2 to 0.6 mm (0.00788 to 0.0236 in.)

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

NOTICE:

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

HINT:

Tape the screwdriver tip before use.

Remove the No. 3 clutch flange, 6 No. 3 clutch discs and 6 No. 3 clutch plates from the reverse clutch drum sub-assembly.

Check whether the sliding surfaces of the No. 3 clutch discs, No. 3 clutch plates and the No. 3 clutch flange are worn or burnt.

NOTICE:

1. If the linings of the No. 3 clutch discs are peeled off or discolored, or if any part of the printed numbers is damaged, replace all the No. 3 clutch discs.
   
2. Before assembling new No. 3 clutch discs, soak them in ATF for at least 2 hours.
   

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

NOTICE:

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

HINT:

Tape the screwdriver tip before use.

Remove the overdrive clutch flange, 6 overdrive direct clutch discs and 6 overdrive direct clutch plates from the overdrive direct clutch drum sub-assembly.

Check whether the sliding surfaces of the overdrive direct clutch discs, overdrive direct clutch plates and the overdrive clutch flange are worn or burnt.

NOTICE:

1. If the linings of the overdrive direct clutch discs are peeled off or discolored, or if any part of the printed numbers is damaged, replace all the overdrive direct clutch discs.
   
2. Before assembling new overdrive direct clutch discs, soak them in ATF for at least 2 hours.
   

Place SST on the reverse clutch balancer, and compress the reverse clutch return spring sub-assembly (rear) with a press.

SST

09380-50010(09381-05020)

Using SST, remove the snap ring.

SST

09350-30020(09350-07070)

Remove the reverse clutch balancer and reverse clutch return spring sub-assembly (rear) from the overdrive direct clutch drum sub-assembly.

While holding the overdrive direct clutch drum sub-assembly, apply compressed air to the oil hole to remove the No. 4 clutch piston.

Remove the O-ring from the No. 4 clutch piston.

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

Standard Free Length:

22.21 mm (0.874 in.)

Remove the overdrive direct clutch drum sub-assembly from the reverse clutch drum sub-assembly.

HINT:

If the overdrive direct clutch drum sub-assembly is difficult to remove, reinstall the snap ring for the overdrive direct clutch discs.

Remove the 3 O-rings from the overdrive direct clutch drum sub-assembly.

Place SST on the No. 3 clutch balancer, and compress the reverse clutch return spring sub-assembly (front) with a press.

SST

09380-50010(09381-05020)

Using SST, remove the snap ring.

SST

09350-30020(09350-07070)

Remove the No. 3 clutch balancer and reverse clutch return spring sub-assembly (front).

Remove the O-ring from the No. 3 clutch balancer.

Hold the reverse clutch drum sub-assembly and apply compressed air to the oil hole of the reverse clutch drum sub-assembly to remove the reverse clutch piston sub-assembly.

Remove the O-ring from the reverse clutch piston sub-assembly.

Remove the O-ring from the reverse clutch drum sub-assembly.

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

Standard Free Length:

21.59 mm (0.850 in.)

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

Standard Inside Diameter (Front Side):

67.40 to 67.44 mm (2.6536 to 2.6551 in.)

Standard Inside Diameter (Rear Side):

55.62 to 55.64 mm (2.1898 to 2.1905 in.)

Remove the forward multiple disc clutch assembly with front planetary ring gear, thrust needle roller bearing and thrust bearing race from the automatic transmission case sub-assembly.

Using needle-nose pliers, detach the snap ring and remove the front planetary ring gear and snap ring from the forward multiple disc clutch assembly.

Using a screwdriver, remove the snap ring.

NOTICE:

Be careful not to damage the forward multiple clutch disc assembly.

HINT:

Tape the screwdriver tip before use.

Remove the forward clutch flange, 7 forward multiple clutch discs and 7 forward multiple clutch plates.

Check whether the sliding surfaces of the forward multiple clutch discs, forward multiple clutch plates and forward clutch flange are worn or burnt.

NOTICE:

1. If the linings of the forward multiple clutch discs are peeled off or discolored, replace all the forward multiple clutch discs.
   
2. Before assembling new forward multiple clutch discs, soak them in ATF for at least 2 hours.
   

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

SST

09380-50010(09381-05020)

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 forward clutch drum sub-assembly.

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

Hold the forward clutch drum sub-assembly and apply compressed air to the oil hole of the forward clutch drum sub-assembly to remove the forward clutch piston.

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

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

Standard Free Length:

20.82 mm (0.820 in.)

Using a caliper gauge, measure the inside diameter of the forward clutch drum bush.

Standard Inside Diameter:

33.200 to 33.225 mm (1.3071 to 1.3080 in.)

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

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

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

Using a caliper gauge, measure the inside diameter of the sun gear input drum bush.

Standard Inside Diameter:

45.066 to 45.091 mm (1.7743 to 1.7752 in.)

Remove the rear planetary sun gear sub-assembly and thrust bearing race from the automatic transmission case sub-assembly.

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

Standard Inside Diameter:

28.760 to 28.781 mm (1.1323 to 1.1331 in.)

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

SST

09350-30020(09350-07060)

Remove the thrust needle roller bearing, rear planetary gear assembly, one-way clutch outer race with No. 1 one-way clutch and thrust bearing race from the automatic transmission case sub-assembly.

Remove the one-way clutch outer race with No. 1 one-way clutch from the rear planetary gear assembly.

Install the No. 1 one-way clutch to the rear planetary gear assembly.

Hold the rear planetary gear assembly and turn the No. 1 one-way clutch.

Text in Illustration

	Lock
	Free

Check that the No. 1 one-way clutch turns freely counterclockwise and locks clockwise.
If the No. 1 one-way clutch does not operate normally, replace it.

Remove the snap ring and No. 1 one-way clutch from the one-way clutch outer race.

Using a feeler gauge, measure the rear planetary gear pinion long and short 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 bush.

Standard Inside Diameter (Front Side):

70.60 to 70.63 mm (2.7796 to 2.7807 in.)

Standard Inside Diameter (Rear Side):

28.700 to 28.721 mm (1.1300 to 1.1307 in.)

Remove the snap ring from the automatic transmission case sub-assembly.

Remove the brake plate, 6 No. 2 brake discs, 5 No. 2 brake plates and No. 2 brake flange from the automatic transmission case sub-assembly.

Check whether the sliding surfaces of the No. 2 brake discs, brake plate, No. 2 brake plates and the No. 2 brake flange are worn or burnt.

NOTICE:

1. If the linings of the No. 2 brake discs are peeled off or discolored, or if any part of the printed numbers is damaged, replace all the No. 2 brake discs.
   
2. Before assembling new discs, soak them in ATF for at least 2 hours.
   

Remove the 2 thrust needle roller bearings, 2 thrust bearing races and direct multiple disc clutch assembly with rear planetary ring gear and output shaft sub-assembly from the automatic transmission case sub-assembly.

Using needle-nose pliers, detach the snap ring and remove the rear planetary ring gear from the output shaft sub-assembly.

Remove the direct multiple disc clutch assembly from the output shaft sub-assembly.

Remove the thrust needle roller bearing and 2 thrust bearing races from the output shaft sub-assembly.

Remove the 2 oil seal ring from the output shaft sub-assembly.

Remove the oil seal ring from the direct multiple disc clutch assembly.

Remove the oil seal ring from the direct multiple disc clutch assembly.

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 No. 2 clutch flange, 7 No. 2 clutch discs and 7 No. 2 clutch plates from the direct clutch drum sub-assembly.

Check whether the sliding surfaces of the No. 2 clutch discs, No. 2 clutch plates and the No. 2 clutch flange are worn or burnt.

NOTICE:

1. If the linings of the No. 2 clutch discs are peeled off or discolored, replace all the No. 2 clutch discs.
   
2. Before assembling new discs, soak them in ATF for at least 2 hours.
   

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

SST

09387-00020

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.

Hold the direct clutch drum sub-assembly and apply compressed air to the oil hole of the direct clutch drum sub-assembly to remove the direct clutch piston.

Remove the O-ring from the direct clutch piston.

Remove the O-ring from the direct clutch drum sub-assembly.

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

Standard Free Length:

20.76 mm (0.817 in.)

Set SST on the No. 2 brake piston return spring sub-assembly, tighten SST and compress the No. 2 brake piston return spring sub-assembly.

SST

09380-50010(09381-05010,09381-05020,09381-05030,09381-05040,09381-05050)

Using SST, remove the snap ring and the No. 2 brake piston return spring sub-assembly.

SST

09350-30020(09350-07070)

Apply compressed air to the oil hole of the automatic transmission case sub-assembly to remove the No. 2 brake piston from the automatic transmission case sub-assembly.

Remove the 3 O-rings from the No. 2 brake piston.

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

Standard Free Length:

23.36 mm (0.920 in.)

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

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

Using SST, remove the output shaft rear radial ball bearing.

SST

09308-00010