БЛОК АВТОМАТИЧЕСКОЙ ТРАНСМИССИИ (для моделей с 2KD-FTV) РАЗБОРКА


  1. REMOVE DRAIN (ATM) PLUG SUB-ASSEMBLY

  2. REMOVE BREATHER PLUG HOSE


    1. A01BD35

      Remove the bolt and breather plug hose from the automatic transmission housing.

  3. REMOVE TRANSMISSION CONTROL SHAFT LEVER LH


    1. A01BFN8

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

  4. REMOVE PARK/NEUTRAL POSITION SWITCH ASSEMBLY


    1. A01BHWF

      Using a screwdriver, unstake the lock washer.

    2. Remove the nut and lock washer.

    3. A01BAP6

      Remove the bolt and the park/neutral position switch.

  5. REMOVE TEMPERATURE SENSOR


    1. A01BCY1

      Remove the temperature sensor.

    2. Remove the O-ring from the temperature sensor.

  6. REMOVE OIL COOLER TUBE UNION


    1. A01BBEV

      Remove the 2 oil cooler tube unions.

    2. Remove the O-rings from each oil cooler tube union.

  7. REMOVE SPEEDOMETER SENSOR (w/ Speedometer Sensor)


    1. A01BCX7E01

      Remove the bolt and the speedometer sensor.

    2. A01BGC3

      Remove the speedometer driven gear from the speedometer sensor.

    3. Remove the O-ring from the speedometer sensor.

  8. REMOVE SPEED SENSOR NC0


    1. A01BCQKE01

      Remove the bolt and the speed sensor NC0.

    2. Remove the O-ring from the speed sensor NC0.

  9. REMOVE SPEED SENSOR SP2


    1. A01BEEHE01

      Remove the bolt and the speed sensor SP2.

    2. Remove the O-ring from the speed sensor SP2.

  10. REMOVE EXTENSION HOUSING SUB-ASSEMBLY


    1. A01BEGH

      Remove the 6 bolts.

    2. Remove the extension housing and the gasket.

  11. REMOVE EXTENSION HOUSING BUSH APPLY TUBE GASKET


    1. A01BDIAE06

      Remove the bush apply tube gasket.

  12. REMOVE EXTENSION HOUSING BUSH APPLY TUBE


    1. A01BDIAE07

      Remove the bush apply tube.

  13. REMOVE AUTOMATIC TRANSMISSION EXTENSION HOUSING OIL SEAL


    1. A01BGPX

      Using a screwdriver, remove the extension housing oil seal.

  14. REMOVE EXTENSION HOUSING DUST (ATM) DEFLECTOR


    1. A01BBVN

      Mount the extension housing in a soft jaw vise.

    2. Using a screwdriver and a hammer, remove the extension housing dust deflector.

  15. INSPECT EXTENSION HOUSING SUB-ASSEMBLY


    1. A01BATM

      Using a cylinder gauge, measure the inside diameter of the extension housing bushing.

      Maximum inside diameter
      40.03 mm (1.5760 in.)

      If the inside diameter is greater than the maximum, replace the extension housing.

  16. REMOVE SPEEDOMETER DRIVE GEAR (w/ Speedometer Sensor)


    1. A01BHAWE01

      Using snap ring expander, remove the snap ring.

    2. Remove the speedometer drive gear and the ball.

  17. REMOVE SENSOR ROTOR (w/ Speedometer Sensor)


    1. A01BB7HE04

      Remove the sensor rotor and the key.

    2. Using snap ring expander, remove the snap ring.

  18. REMOVE SENSOR ROTOR (w/o Speedometer Sensor)


    1. A01BE6SE04

      Using snap ring expander, remove the rear side snap ring.

    2. Remove the sensor rotor and the key.

    3. Using snap ring expander, remove the front side snap ring.

  19. REMOVE AUTOMATIC TRANSMISSION HOUSING


    1. A01BHUQ

      Remove the 6 bolts.

    2. Remove the transmission housing.

  20. FIX AUTOMATIC TRANSMISSION CASE SUB-ASSEMBLY


    1. A01BF3I

      Install the transmission case on the overhaul attachment.

  21. REMOVE AUTOMATIC TRANSMISSION OIL PAN SUB-ASSEMBLY


    1. A01BA82

      Remove the 19 bolts.

      Note

      Do not turn the transmission over as this will contaminate the valve body with any foreign matter at the bottom of the pan.

    2. A01BCOUE03

      Install the blade of SST between the transmission case and the oil pan, and cut off the applied sealer.

      Note

      Be careful not to damage the oil pan and flange.

    3. Remove the pan by lifting the transmission case.

  22. INSPECT AUTOMATIC TRANSMISSION OIL PAN SUB-ASSEMBLY


    1. A01BER6

      Remove the oil cleaner magnets, and use them to collect steel particles.

      Carefully lock at the foreign matter and particles in the pan and on the oil cleaner magnets to anticipate the type of wear you will find in the transmission.

      Steel (magnetic)
      Bearing, gear and clutch plate wear
      Brass (non-magnetic)
      Bushing wear

  23. REMOVE VALVE BODY OIL STRAINER ASSEMBLY


    1. A01BCEM

      Remove the 4 bolts holding the oil strainer to the valve body.

    2. Remove the oil strainer and the 5 gaskets.

  24. REMOVE TRANSMISSION WIRE


    1. A01BESI

      Disconnect the 4 connectors from each shift solenoid valve.

    2. A01BGDS

      Remove the bolt.

    3. Pull out the solenoid wiring from the transmission case.

    4. Remove the O-rings from the solenoid wiring.

  25. REMOVE TRANSMISSION VALVE BODY ASSEMBLY


    1. A01BDN0

      Remove the 20 bolts and the valve body.

  26. REMOVE CHECK BALL BODY


    1. A01BGN3

      Remove the check ball body and the spring.

  27. REMOVE B-2 ACCUMULATOR PISTON


    1. A01BH94

      Applying compressed air (392 kPa, 4.0 kgf/cm2, 57 psi) to the oil hole, remove the B2 accumulator piston and the spring.

      Note


      • Blowing off the air may cause the piston to jump out. When removing the piston, hold it by hand using a waste cloth.

      • Take care not to splash ATF when air-blowing.

    2. Remove the 2 O-rings from the B2 accumulator piston.

  28. REMOVE C-2 ACCUMULATOR PISTON


    1. A01BH94

      Applying compressed air (392 kPa, 4.0 kgf/cm2, 57 psi) to the oil hole, remove the C2 accumulator piston and the springs.

      Note


      • Blowing off the air may cause the piston to jump out. When removing the piston, hold it by hand using a waste cloth.

      • Take care not to splash ATF when air-blowing.

    2. Remove the 2 O-rings from the C2 accumulator piston.

  29. REMOVE B-0 ACCUMULATOR PISTON


    1. A01BGWQ

      Applying compressed air (392 kPa, 4.0 kgf/cm2, 57 psi) to the oil hole, remove the B0 accumulator piston and the spring.

      Note


      • Blowing off the air may cause the piston to jump out. When removing the piston, hold it by hand using a waste cloth.

      • Take care not to splash ATF when air-blowing.

    2. Remove the 2 O-rings from the B0 accumulator piston.

  30. REMOVE C-0 ACCUMULATOR PISTON


    1. A01BE9R

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

      Note


      • The application of compressed air may cause the piston to jump out. When removing the piston, hold it using a shop rag or piece of cloth.

      • Take care not to splash ATF when applying compressed air.

    2. Remove the O-ring from the C-0 accumulator piston.

  31. REMOVE PARKING LOCK PAWL BRACKET


    1. A01BEL2

      Remove the 3 bolts and the parking lock pawl bracket.

  32. REMOVE PARKING LOCK ROD SUB-ASSEMBLY


    1. A01BBYT

      Disconnect the parking lock rod from the manual valve lever.

  33. REMOVE PARKING LOCK PAWL SHAFT


    1. A01BFZDE02

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

    2. Remove the E-ring from the shaft.

  34. REMOVE MANUAL VALVE LEVER SUB-ASSEMBLY


    1. A01BA9TE02

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

    2. A01BB38

      Using a pin punch and hammer, drive out the pin.

      Tech Tips

      Slowly drive out the pin so that it does not fall into the transmission case.

    3. Pull out the manual valve lever shaft through the case, and remove the manual valve lever.

  35. REMOVE MANUAL VALVE LEVER SHAFT OIL SEAL


    1. A01BFQQ

      Using screwdriver, remove the 2 manual valve lever shaft oil seals.

  36. REMOVE OIL PUMP ASSEMBLY


    1. A01BGSN

      Stand up the transmission.

    2. Remove the 7 bolts holding the oil pump to the transmission case.

    3. A01BE90E02

      Using SST, remove the oil pump.

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

    5. A01BC3N

      Remove the race from the oil pump.

  37. REMOVE OVERDRIVE PLANETARY GEAR ASSEMBLY


    1. A01BESF

      Remove the O/D planetary gear, O/D direct clutch and one-way clutch from the transmission case.

    2. A01BALK

      Remove the race and the bearing.

  38. REMOVE OVERDRIVE PLANETARY RING GEAR


    1. A01BFK6

      Remove the O/D planetary ring gear from the transmission case.

    2. A01BA4BE01

      Remove the bearing and the 2 races from the O/D planetary ring gear.

  39. REMOVE OVERDRIVE BRAKE PISTON


    1. A01BB0CE02

      Place SST and a dial indicator onto the O/D brake piston.

      SST
      09350-30020   ( 09350-06120 )
    2. A01BBUU

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

      Piston stroke
      1.75 to 2.05 mm (0.0689 to 0.0807 in.)

      If the stroke is outside the standard, inspect the discs.

  40. REMOVE OVERDRIVE BRAKE PACK


    1. A01BD5T

      Using a screwdriver, remove the snap ring.

    2. A01BB3M

      Remove the O/D brake pack.

  41. INSPECT PISTON STROKE OF 2ND COST BRAKE


    1. A01BA61E02

      Place a mark on the 2nd coast brake piston rod.

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

      SST
      09240-00020
      Piston rod stroke
      1.5 to 3.0 mm (0.059 to 0.118 in.)

      If the stroke is more than the specified, replace the piston rod.

      Piston rod length
      78.4 mm (3.087 in.)
      79.9 mm (3.146 in.)

      If the stroke is still more than the standard value, replace the brake band with a new one.

  42. REMOVE OVERDRIVE SUPPORT SUB-ASSEMBLY


    1. A01BA5C

      Remove the 2 bolts holding the O/D support assembly from the case.

    2. A01BDHTE02

      Using SST, remove the snap ring.

      SST
      09350-30020   ( 09350-07020, 09350-07060 )
    3. A01BBBGE02

      Using SST, remove the O/D support assembly.

      SST
      09350-30020   ( 09350-07020 )
    4. A01BAAVE02

      Remove the bearing and the race from the O/D support.

  43. REMOVE 2ND COAST BRAKE PISTON


    1. A01BG3NE02

      Using SST, remove the snap ring.

      SST
      09350-30020   ( 09350-07060 )
    2. A01BC7R

      Applying compressed air (392 kPa, 4.0 kgf/cm2, 57 psi) to the oil hole, remove the 2nd coast brake cover, the piston assembly and the spring.

    3. Remove the 2 O-rings from the cover.

  44. REMOVE DIRECT CLUTCH ASSEMBLY


    1. A01BHGL

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

    2. Remove the bearing from the direct clutch.

  45. REMOVE FORWARD CLUTCH ASSEMBLY


    1. A01BEYDE02

      Remove the direct clutch from the forward clutch.

    2. A01BDS5E04

      Remove the bearing, thrust washer and the race from the forward clutch.

  46. REMOVE 2ND COAST BRAKE BAND ASSEMBLY


    1. A01BGNC

      Using a screwdriver, remove the E-ring from the pin.

      Tech Tips

      Apply the grease to the E-ring and the pin before the work so that the ring does not fly out.

    2. Remove the pin from the brake band.

    3. Remove the E-ring from the pin.

    4. A01BF6G

      Remove the 2nd coast brake band from the case.

  47. REMOVE FRONT PLANETARY RING GEAR SUB-ASSEMBLY


    1. A01BAHU

      Remove the front planetary ring gear from the case.

    2. A01BER3

      Remove the 2 bearings and the race from the front planetary ring gear.

    3. A01BHGT

      Remove the race from the front planetary gear.

    4. A01BEVNE02

      With wooden blocks or equivalent under the output shaft, stand the transmission on the output shaft.

  48. INSPECT FRONT PLANETARY RING GEAR SUB-ASSEMBLY


    1. A01BDKA

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

      Maximum inside diameter
      24.65 mm (0.9705 in.)

      If the inside diameter is greater than the maximum, replace the planetary ring gear.

  49. REMOVE FRONT PLANETARY GEAR ASSEMBLY


    1. A01BAOXE02

      Using SST, remove the snap ring.

      SST
      09350-30020   ( 09350-07070 )

      Tech Tips

      Pushing the output shaft towards the front makes it easier to remove the snap ring.

    2. A01BE32

      Remove the front planetary gear from the case.

    3. A01BBA1

      Using a screwdriver, remove the bearing and the race from the front planetary gear.

  50. INSPECT PLANETARY PINION GEAR THRUST CLEARANCE


    1. A01BBP7

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

      Standard clearance
      0.20 - 0.60 mm (0.0079 - 0.0236 in.)
      Maximum clearance
      0.65 mm (0.0256 in.)

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

  51. REMOVE PLANETARY SUN GEAR SUB-ASSEMBLY


    1. A01BF6EE02

      Remove the planetary sun gear and 1 way clutch from the case.

    2. Remove the thrust washer.

  52. INSPECT PACK CLEARANCE OF SECOND BRAKE


    1. A01BBCB

      Using a feeler gauge, measure the clearance between the snap ring and the flange.

      Clearance
      0.62 to 1.98 mm (0.0244 to 0.0780 in.)

      If the clearance is outside the standard, check for an improper installation.

  53. REMOVE 2ND BRAKE PACK


    1. A01BCCA

      Using a screwdriver, remove the snap ring.

    2. A01BCJAE03

      Remove the 2nd brake pack.

  54. REMOVE PACK CLEARANCE OF FIRST AND REVERSE BRAKE


    1. A01BDE3

      Using a feeler gauge, measure the clearance between the plate and the 2nd brake drum.

      Clearance
      0.70 to 1.22 mm (0.0276 to 0.048 in.)

      If the clearance is non-standard, inspect the discs.

  55. REMOVE 2ND BRAKE PISTON SLEEVE


    1. A01BEJQ

      Using a screwdriver, remove the 2nd brake piston sleeve.

  56. REMOVE REAR PLANETARY GEAR ASSEMBLY


    1. A01BABCE02

      Using SST and a screwdriver, remove the snap ring.

      SST
      09350-30020   ( 09350-07060 )
    2. A01BDAF

      Remove the 2nd brake drum, the 1st and reverse brake pack and the rear planetary gear and output shaft.

    3. A01BCDA

      Remove the bearing from the case.

    4. A01BHGO

      Remove the 2nd brake drum.

    5. A01BF8I

      Remove the cushion plate, the flange, the plates and the discs of the 1st and reverse brake.

    6. A01BEO8

      Remove the leaf spring.

  57. INSPECT 1ST AND REVERSE BRAKE CLUTCH DISK


    1. A01BEPDE02

      Check if the sliding surfaces of the disc, the plate and the flange are worn or burnt. If necessary, replace them.

      Tech Tips


      • If the lining of the disc is peeled off or discolored, or even if only a part of the printed numbers is corroded, replace all discs.

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

  58. REMOVE BRAKE DRUM GASKET

  59. INSPECT PISTON STROKE OF 1ST AND REVERSE BRAKE


    1. A01BBIL

      Make sure the 1st and reverse brake pistons move smoothly when applying and releasing the compressed air into the transmission case.

  60. REMOVE 1ST AND REVERSE BRAKE RETURN SPRING SUB-ASSEMBLY


    1. A01BGSGE02

      Set SST on the spring retainer, and compress the return spring.

      Note

      Stop compressing when the spring sheet is lowered to the place 1 to 2 mm (0.039 to 0.078 in.) from the snap ring groove, preventing the spring sheet from being deformed.

    2. Using snap ring pliers, remove the snap ring.

    3. Remove the piston return spring.

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

  61. INSPECT 1ST AND REVERSE BRAKE RETURN SPRING SUB-ASSEMBLY


    1. A01BGSDE02

      Check the return spring free length together with the spring seat.

      Standard free length
      12.9 mm (0.508 in.)

  62. REMOVE 1ST AND REVERSE BRAKE PISTON NO.2


    1. A01BD18

      Remove the 1st and reverse brake piston.

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

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

  63. REMOVE BRAKE REACTION SLEEVE


    1. A01BC77E02

      Install SST behind the reaction sleeve and gradually lift it out of the transmission case.

      SST
      09350-30020   ( 09350-07080 )

    2. Remove the O-ring from the reaction sleeve.

  64. REMOVE 1ST AND REVERSE BRAKE PISTON NO.1


    1. A01BCUWE02

      Install SST behind the No.1 1st and reverse brake piston No.1 and gradually lift it out of the transmission case.

      SST
      09350-30020   ( 09350-07090 )

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

  65. INSPECT AUTOMATIC TRANSMISSION CASE SUB-ASSEMBLY


    1. A01BB7Z

      Using a cylinder gauge, measure the inside diameter of the transmission case rear bushing.

      Maximum inside diameter
      38.19 mm (1.5035 in.)

      If the inside diameter is greater than the maximum, replace the transmission case.