Automatic Transmission Unit Disassembly

Remove the 2 bolts and transaxle case cover upper.

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

Using a screwdriver, unstake the lock washer.

Remove the nut and lock washer.

Remove the bolt and park/neutral position switch.

Remove the 2 oil cooler tube unions.

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

Remove the 2 bolts and the 2 transmission revolution sensors.

Remove the O-rings from each sensor.

Remove the 2 bolts.

Remove the breather tube.

Remove the 10 bolts.

Remove the transmission housing.

Using a hammer and chisel, loosen the staked part of the nut.

Remove the nut and flange yoke.

Remove the oil seal from the flange yoke.

Remove the 6 bolts.

Use a screwdriver to remove the extension housing sub-assembly.

Using a snap ring expander, remove the snap ring.

Remove the thrust needle roller bearing and the 2 bearing races.

Remove the 2 washers and RR cover sleeve.

Remove the transmission case adaptor radial ball bearing from the extension housing sub-assembly.

Using a screwdriver, remove the oil seal.

Install the transmission case on the overhaul attachment.

Remove the over flow plug and the gasket.

Remove the drain plug and the gasket.

Remove the 20 bolts, oil pan and gasket.

Examine particles in the pan.

1. Remove the magnets from the oil pan. Use the removed magnets to collect any steel chips. Look carefully at the chips and particles in the pan and on the magnet to anticipate the type of wear which might be found in the transmission.
   Steel (magnetic): bearing, gear and plate wear
   Brass (non-magnetic): bearing wear
   

Turn over the transmission.

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

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

Remove the 3 bolts and disconnect the 3 clamps.

Disconnect the 9 connectors from the shift solenoid valves.

Remove the bolt from the transmission case.

Pull the transmission wire out of the transmission case.

Remove the O-ring from the transmission wire.

Remove the bolt, the detent spring cover and detent spring.

Remove the 20 bolts.

Remove the valve body assembly.

Remove the 3 transaxle case gaskets.

Remove the 3 brake drum gaskets.

Remove the check ball body and the spring.

While blowing compressed air into the oil hole, remove the C-2 accumulator piston and the spring.

Remove the 2 O-rings from the piston.

NOTICE:

The C-3 and B-3 accumulator piston may jump out.

While blowing compressed air into the oil hole, remove the B-3 accumulator piston and the spring.

Remove the 2 O-rings from the piston.

NOTICE:

The C-3 accumulator piston may jump out.

While blowing compressed air into the oil hole, remove the C-3 accumulator piston and the 2 springs.

Remove the 2 O-rings from the piston.

Remove the B-1 accumulator valve and the 2 springs.

Remove the 3 bolts and the 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, then remove the lock pawl and the spring.

Remove the E-ring from the shaft.

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

Using a pin punch and a hammer, drive 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 from the transmission case.

Using a screwdriver with its tip wrapped with tape, pull out the oil pump.

NOTICE:

Do not damage the oil pump.

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

Remove the O-ring from the oil pump.

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

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

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

Check that the 1 way No.2 clutch assembly turns freely clockwise and locks counterclockwise.
If there is a problem with the 1 way clutch, replace it.

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

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

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

Check whether the sliding surfaces of the discs, the plates, or the flange are worn or burnt.
If necessary, replace them.

NOTICE:

1. If the linings of the discs are peeled off or discolored, or if any part of the printed numbers is damaged, replace all discs.
   
2. 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 planetary carrier thrust washer No.1 from the transmission case.

Remove the 2nd brake cylinder from the transmission case.

Using SST and a press, remove the 2nd brake piston snap ring.

SST

09351-40010(09351-04060,09351-04070)

Remove the brake piston return spring sub-assembly No.3.

Hold the 2nd brake piston 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 vernier calipers, 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 the 1 way clutch inner race from the transmission case.

Remove the thrust needle roller bearing, the thrust bearing race No.3 and the planetary carrier thrust washer No.2 from the transmission case.

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

Standard clearance:

0.20 to 0.60 mm (0.008 to 0.024 in.)

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

Standard inside diameter:

57.43 mm (2.261 in.)

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 clockwise.
If there is a problem with the 1 way clutch, replace it.

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

Remove the front planetary ring gear from the transmission case.

Using a screwdriver, remove the snap ring.

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

Remove the thrust needle roller bearing from the front planetary ring gear flange.

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

Check whether the sliding surfaces of the discs, the plates, or the flange are worn or burnt.
If necessary, replace them.

NOTICE:

1. If the linings of the discs are peeled off or discolored, or if any part of the groove is damaged, replace all discs.
   
2. 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 transmission case.

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

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

Standard free length:

17.05 mm (0.671 in.)

Hold the brake cylinder No.1 and apply compressed air (392 kPa, 4 kgf/cm², 57 psi) to the brake cylinder No.1 to remove the brake piston No.1.

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 brake piston No.1.

Using a screwdriver, remove the brake No.2 snap ring from the transmission case.

Remove the 2 flanges, the brake piston return spring, the 4 discs and the 3 plates from the transmission case.

Check whether the sliding surfaces of the discs, the plates, and the flange are worn or burnt.
If necessary, replace them.

NOTICE:

1. If the linings of the discs are peeled off or discolored, or if any part of the printed numbers is damaged, replace all discs.
   
2. Before assembling new discs, soak them in ATF for at least 15 minutes.
   

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

Standard free length:

22.66 mm (0.8921 in.)

Hold the brake piston No.2 and apply compressed air (392 kPa, 4 kgf/cm², 57 psi) to the transmission case to remove the brake piston No.2 with the cylinder.

HINT:

If the piston does not pop out with compressed air, lift the piston out with needle-nose pliers.

Remove the piston from the cylinder.

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

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

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

Standard clearance:

0.12 to 0.68 mm (0.005 to 0.027 in.)

Using SST, remove the snap ring from the transmission case.

SST

09350-30020(09350-07060)

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

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

Check that the 1 way clutch assembly turns freely counterclockwise and locks clockwise.
If there is a problem with the 1 way clutch, replace it.

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

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

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

Standard inside diameter:

32.19 mm (1.2673 in.)

Using a dial indicator, check the intermediate shaft runout.

Standard runout:

0.03mm (0.0012 in.)

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

Standard diameter:

A:

25.962 to 25.975 mm (1.022 to 1.023 in.)

B:

25.962 to 25.975 mm (1.022 to 1.023 in.)

C:

32.062 to 32.075 mm (1.262 to 1.263 in.)

D:

32.062 to 32.075 mm (1.262 to 1.263 in.)

Remove the brake plate stopper spring from the transmission case.

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

Check whether the sliding surfaces of the discs, the plates, and the flange are worn or burnt.
If necessary, replace them.

NOTICE:

1. If the linings of the discs are peeled off or discolored, or if any part of the printed numbers is damaged, replace all discs.
   
2. Before assembling new discs, soak them in ATF for at least 15 minutes.
   

Remove the rear planetary gear assembly from the transmission case.

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

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

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

Standard clearance:

0.2 to 0.6 mm (0.008 to 0.024 in.)

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

Standard inside diameter:

20.025 mm (0.7884 in.)

Place SST on the 1st and reverse brake return spring sub-assembly 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 vernier calipers, measure the free length of the spring together with the spring seat.

Standard free length:

23.74 mm (0.935 in.)

Hold the 1st and reverse brake piston and blow compressed air (392 kPa, 4 kgf/cm², 57 psi) into 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 brake apply tube from the piston.

Remove the O-ring from the 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 No.4.

SST

09350-30020(09350-07080)

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