AUTOMATIC TRANSMISSION UNIT DISASSEMBLY


  1. REMOVE TRANSMISSION CONTROL SHAFT LEVER RH


    1. A01GIOQ

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

  2. REMOVE PARK/NEUTRAL POSITION SWITCH ASSEMBLY

    A01GMZT

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

    2. Remove the nut and lock washer.

    3. Remove the bolt and park/neutral position switch assembly.

  3. REMOVE OIL COOLER TUBE UNION

    A01GN17

    1. Remove the 2 oil cooler tube elbows.

    2. Remove the O-rings from the oil cooler tube elbows.

  4. REMOVE NO. 1 BREATHER PLUG

    A01GKZ7

  5. REMOVE AUTOMATIC TRANSMISSION OIL PAN SUB-ASSEMBLY

    Note

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


    1. Remove the overflow plug and gasket.

    2. Remove the drain plug and gasket.

    3. A01GN2W

      Remove the 9 bolts, automatic transmission oil pan and gasket.

    4. Examine the 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): bush wear

  6. REMOVE VALVE BODY OIL STRAINER ASSEMBLY

    A01GKXI

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

    2. A01GLWT

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

  7. REMOVE TRANSMISSION VALVE BODY ASSEMBLY


    1. A01GLSS

      Remove the bolt, lock plate and ATF temperature sensor.

    2. Remove the oil pressure switch connector.

    3. Disconnect the 9 connectors from the solenoid valves.

    4. A01GHP8

      Remove the bolt, detent spring cover and detent spring.

    5. A01GKDH

      Remove the 17 bolts and transmission valve body assembly.

      Note

      Do not drop the check ball body or spring.

    6. Disconnect the lever pin from the manual valve.

      Note

      Do not drop the manual valve.

  8. REMOVE CHECK BALL BODY

    A01GM97

    1. Remove the check ball body and spring.

  9. REMOVE TRANSMISSION WIRE

    A01GL12

    1. Disconnect the 3 connectors from the 3 speed sensors.

    2. A01GHTQ

      Remove the bolt and pull out the transmission wire.

  10. REMOVE SPEED SENSOR

    A01GIUFE01

    1. Remove the 2 bolts and 2 speed sensors (NC3 and SP2).

    2. Using a T30 ''TORX'' wrench, remove the bolt and speed sensor NT.

  11. REMOVE AUTOMATIC TRANSMISSION CASE PLUG

    A01GJAU

    1. Remove the automatic transmission case plug and O-ring.

  12. REMOVE PARKING LOCK PAWL BRACKET

    A01GMYA

    1. Remove the 3 bolts and parking lock pawl bracket.

  13. REMOVE PARKING LOCK ROD SUB-ASSEMBLY

    A01GJFWE01

    1. Disconnect the parking lock rod from the manual valve lever.

  14. REMOVE PARKING LOCK PAWL SHAFT

    A01GLKLE01

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

    2. Remove the E-ring from the shaft.

  15. REMOVE MANUAL VALVE LEVER SUB-ASSEMBLY

    A01GHVU

    1. Using a screwdriver and hammer, cut off the spacer and remove it from the manual valve lever shaft.

    2. A01GO0T

      Using a pin punch and hammer, tap out the spring pin.

      Tech Tips

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

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

  16. REMOVE MANUAL VALVE LEVER SHAFT OIL SEAL


    1. A01GHLLE01
      Text in Illustration
      *1 Protective Tape

      Using a screwdriver, pry out the oil seal.

      Tech Tips

      Tape the screwdriver tip before use.

  17. REMOVE OIL PUMP ASSEMBLY

    A01GND0

    1. Remove the 11 bolts from the transmission case.

    2. A01GNT5

      Pull out the oil pump assembly.

      Note

      Do not damage the oil pump assembly.

    3. A01GNSN

      Remove the O-ring from the oil pump assembly.

  18. REMOVE OVERDRIVE AND REVERSE CLUTCH DRUM SUB-ASSEMBLY AND FRONT PLANETARY GEAR ASSEMBLY WITH NO. 1 BRAKE DISC SET

    A01GLYO

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

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

  19. REMOVE NO. 1 BRAKE DISC SET


    1. Remove the 5 plates, 5 discs and No. 1 brake flange.

  20. INSPECT NO. 1 BRAKE DISC

    A01GNP6

    1. Replace all No. 1 brake discs if one of the following problems is present: 1) a No. 1 brake disc, No. 1 brake plate or No. 1 brake flange is worn or burnt; 2) the lining of a No. 1 brake disc is peeled off or discolored; or 3) the grooves or printed numbers have even a little bit of damage.

      Note

      Before assembling new No. 1 brake discs, soak them in ATF for at least 2 hours.

  21. REMOVE FRONT PLANETARY GEAR ASSEMBLY

    A01GMBK

    1. Remove the front planetary gear assembly with the front planetary sun gear from the overdrive and reverse clutch drum sub-assembly.

    2. A01GL6K

      Remove the 3 clutch drum oil seal rings.

    3. A01GNZ9

      Remove the planetary carrier thrust washer.

    4. A01GHL4

      Remove the 2 clutch drum oil seal rings.

    5. A01GM4Q

      Remove the planetary sun gear.

  22. INSPECT FRONT PLANETARY GEAR ASSEMBLY

    A01GM4V

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

      Standard clearance
      0.2 to 0.6 mm (0.00787 to 0.0236 in.)

      If the clearance is not as specified, replace the front planetary gear assembly.

  23. REMOVE OVERDRIVE CLUTCH DISC SET


    1. A01GJONE01
      Text in Illustration
      *1 Protective Tape

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

      Tech Tips

      Tape the screwdriver tip before use.

    2. Remove the flange, 4 discs and 4 plates from the drum.

  24. INSPECT OVERDRIVE CLUTCH DISC

    A01GI1M

    1. Replace all overdrive clutch discs if one of the following problems is present: 1) an overdrive clutch disc, overdrive brake clutch plate or overdrive clutch flange is worn or burnt; 2) the lining of an overdrive clutch disc is peeled off or discolored; or 3) the grooves or printed numbers have even a little bit of damage.

      Note

      Before assembling new overdrive clutch discs, soak them in ATF for at least 2 hours.

  25. REMOVE REVERSE CLUTCH DISC SET


    1. A01GJZ8E01
      Text in Illustration
      *1 Protective Tape

      Using a screwdriver, remove the hole snap ring from the reverse clutch drum.

      Tech Tips

      Tape the screwdriver tip before use.

    2. Remove the flange, 5 discs, 5 plates and cushion plate from the reverse clutch drum.

  26. INSPECT REVERSE CLUTCH DISC

    A01GNI1

    1. Replace all reverse clutch discs if one of the following problems is present: 1) a reverse clutch disc, reverse clutch plate or reverse clutch flange is worn or burnt; 2) the lining of a reverse clutch disc is peeled off or discolored; or 3) the grooves or printed numbers have even a little bit of damage.

      Note

      Before assembling new reverse clutch discs, soak them in ATF for at least 2 hours.

  27. REMOVE REVERSE CLUTCH PISTON

    A01GL80E01

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

      SST
      09380-50010

    2. Using SST, remove the snap ring.

      SST
      09350-30020   ( 09350-07070 )
    3. A01GLB3

      Remove the reverse clutch balancer and reverse clutch return spring sub-assembly from the reverse clutch drum.

    4. A01GLSVE02
      Text in Illustration
      *1 Oil Hole

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

    5. Remove the O-ring from the reverse clutch piston.

  28. INSPECT REVERSE CLUTCH RETURN SPRING SUB-ASSEMBLY

    A01GL6W

    1. Using a vernier caliper, measure the free length of the reverse clutch return spring sub-assembly together with the spring seat.

      Standard free length
      22.21 mm (0.874 in.)

      If the free length is shorter than the standard free length, replace the reverse clutch return spring sub-assembly.

  29. REMOVE REVERSE CLUTCH DRUM SUB-ASSEMBLY

    A01GM1K

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

      Tech Tips

      The reverse clutch drum is easier to remove if a hole snap ring is installed. Use the hole snap ring from the "REMOVE REVERSE CLUTCH DISC SET" procedure.

    2. Remove the 3 O-rings from the reverse clutch drum.

  30. REMOVE OVERDRIVE DIRECT CLUTCH PISTON SUB-ASSEMBLY

    A01GNPOE01

    1. Place SST on the No. 3 clutch balancer and compress the overdrive clutch return spring with a press.

      SST
      09380-50010

    2. Using SST, remove the snap ring.

      SST
      09350-30020   ( 09350-07070 )
    3. A01GHRA

      Remove the No. 3 clutch balancer and overdrive clutch return spring.

    4. A01GKQ5E02
      Text in Illustration
      *1 Oil Hole

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

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

    6. Remove the O-ring from the overdrive direct clutch piston sub-assembly.

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

  31. INSPECT OVERDRIVE CLUTCH RETURN SPRING SUB-ASSEMBLY

    A01GI6A

    1. Using a vernier caliper, measure the free length of the overdrive clutch return spring sub-assembly together with the spring seat.

      Standard free length
      21.09 mm (0.830 in.)

      If the free length is shorter than the standard free length, replace the overdrive clutch return spring sub-assembly.

  32. INSPECT OVERDRIVE DIRECT CLUTCH DRUM SUB-ASSEMBLY

    A01GNR3

    1. Using a caliper gauge, measure the inside diameter of the overdrive direct clutch drum bush.

      Standard inside diameter for front side
      67.40 to 67.44 mm (2.654 to 2.655 in.)
      Standard inside diameter for rear side
      55.62 to 55.64 mm (2.1898 to 2.1905 in.)

      If the inside diameter is not as specified, replace the overdrive direct clutch drum sub-assembly.

  33. REMOVE FORWARD MULTIPLE DISC CLUTCH SUB-ASSEMBLY WITH FRONT PLANETARY RING GEAR

    A01GMJ7

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

    2. A01GLRS

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

  34. REMOVE FORWARD MULTIPLE CLUTCH DISC SET


    1. A01GNV8E01
      Text in Illustration
      *1 Protective Tape

      Using a screwdriver, remove the snap ring.

      Tech Tips

      Tape the screwdriver tip before use.

    2. Remove the forward clutch flange, 6 forward multiple disc clutch clutch discs, 6 forward multiple disc clutch clutch plates and clutch cushion plate.

  35. INSPECT FORWARD MULTIPLE DISC CLUTCH CLUTCH DISC

    A01GN4N

    1. Replace all forward multiple clutch clutch discs if one of the following problems is present: 1) a forward multiple clutch clutch disc, forward multiple clutch clutch plate or forward clutch flange is worn or burnt; 2) the lining of a forward multiple clutch clutch disc is peeled off or discolored; or 3) the grooves or printed numbers have even a little bit of damage.

      Note

      Before assembling new forward multiple clutch clutch discs, soak them in ATF for at least 2 hours.

  36. REMOVE FORWARD CLUTCH PISTON

    A01GL2PE01

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

      SST
      09380-50010

    2. Using SST, remove the snap ring.

      SST
      09350-30020   ( 09350-07070 )
    3. A01GIRJ

      Remove the No. 1 clutch balancer and forward clutch return spring sub-assembly from the forward clutch drum sub-assembly.

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

    5. A01GHJBE02
      Text in Illustration
      *1 Oil Hole

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

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

  37. INSPECT FORWARD CLUTCH RETURN SPRING SUB-ASSEMBLY

    A01GMJH

    1. Using a vernier caliper, measure the free length of the forward clutch return spring sub-assembly together with the spring seat.

      Standard free length
      20.82 mm (0.820 in.)

      If the free length is shorter than the standard free length, replace the forward clutch return spring sub-assembly.

  38. INSPECT FORWARD CLUTCH DRUM SUB-ASSEMBLY

    A01GK3C

    1. 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 1.3081 in.)

      If the inside diameter is not as specified, replace the forward clutch drum sub-assembly.

  39. REMOVE MULTIPLE DISC CLUTCH CLUTCH HUB

    A01GKNW

    1. Remove the multiple disc clutch clutch hub from the transmission case.

    2. Remove the thrust bearing race and thrust needle roller bearing from the transmission case.

  40. REMOVE SUN GEAR INPUT DRUM SUB-ASSEMBLY

    A01GHZP

    1. Remove the sun gear input drum, thrust needle roller bearing and thrust bearing race from the transmission case.

  41. INSPECT SUN GEAR INPUT DRUM SUB-ASSEMBLY

    A01GLDC

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

      Standard inside diameter
      45.075 to 45.100 mm (1.7746 to 1.7756 in.)

      If the inside diameter is not as specified, replace the sun gear input drum sub-assembly.

  42. REMOVE REAR PLANETARY SUN GEAR ASSEMBLY

    A01GN8F

    1. Remove the rear planetary sun gear assembly and thrust bearing race from the transmission case.

  43. REMOVE 1-WAY CLUTCH OUTER RACE WITH NO. 1 1-WAY CLUTCH

    A01GK35E01

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

      SST
      09350-30020   ( 09350-07060 )
    2. A01GKA0

      Remove the 1-way clutch outer race with No. 1 1-way clutch.

  44. INSPECT REAR PLANETARY SUN GEAR ASSEMBLY

    A01GM6P

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

      Standard inside diameter
      28.700 to 28.721 mm (1.1299 to 1.1307 in.)

      If the inside diameter is not as specified, replace the rear planetary sun gear assembly.

  45. REMOVE REAR PLANETARY GEAR ASSEMBLY

    A01GMVQ

    1. Remove the thrust needle roller bearing, rear planetary gear assembly and thrust bearing race from the transmission case.

  46. INSPECT NO. 1 1-WAY CLUTCH


    1. Set the No. 1 1-way clutch against the rear planetary gear assembly.

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

    3. A01GNVCE02
      Text in Illustration
      *a Free
      *b Lock

      Check that the No. 1 1-way clutch turns freely when turned counterclockwise and locks when turned clockwise.

      If there is a problem with the No. 1 1-way clutch, replace it.

  47. REMOVE NO. 1 1-WAY CLUTCH

    A01GJ8B

    1. Remove the 2 snap rings from the 1-way clutch outer race.

  48. INSPECT REAR PLANETARY GEAR ASSEMBLY

    A01GO0U

    1. Using a feeler gauge, measure the thrust clearance of both the long and short planetary pinion gears of the rear planetary pinion gear assembly.

      Standard clearance
      0.2 to 0.6 mm (0.00787 to 0.0236 in.)

      If the clearance is not as specified, replace the rear planetary gear assembly.

    2. A01GMDD

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

      Standard inside diameter for front side
      71.60 to 71.63 mm (2.8189 to 2.8201 in.)
      Standard inside diameter for rear side
      28.700 to 28.721 mm (1.1299 to 1.1307 in.)

      If the inside diameter is not as specified, replace the rear planetary gear assembly.

  49. REMOVE NO. 2 BRAKE DISC SET


    1. Remove the brake plate, 4 No. 2 brake discs, 3 No. 2 brake plates and No. 2 brake flange.

  50. INSPECT NO. 2 BRAKE DISC

    A01GMS9

    1. Replace all No. 2 brake discs if one of the following problems is present: 1) a No. 2 brake disc, No. 2 brake plate or No. 2 brake 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.

      Note

      Before assembling new No. 2 brake discs, soak them in ATF for at least 2 hours.

  51. REMOVE DIRECT CLUTCH DRUM SUB-ASSEMBLY WITH REAR PLANETARY RING GEAR AND OUTPUT SHAFT SUB-ASSEMBLY

    A01GJWD

    1. Remove the 2 thrust needle roller bearings, the 2 thrust bearing races and the direct clutch drum with rear planetary ring gear and output shaft from the transmission case.

  52. REMOVE REAR PLANETARY RING GEAR


    1. A01GJDH

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

  53. DISCONNECT DIRECT CLUTCH DRUM SUB-ASSEMBLY

    A01GLOK

    1. Disconnect the direct clutch drum from the output shaft and remove the thrust needle roller bearing and thrust bearing race from the output shaft.

    2. A01GNV2

      Remove the 3 oil seal rings from the output shaft.

    3. A01GN16

      Remove the 2 oil seal rings from the direct clutch drum.

  54. REMOVE NO. 2 CLUTCH DISC SET


    1. A01GMBBE01
      Text in Illustration
      *1 Protective Tape

      Using a screwdriver, remove the snap ring, direct clutch flange, 6 No. 2 clutch discs and 6 No. 2 clutch plates from the direct clutch drum.

      Tech Tips

      Tape the screwdriver tip before use.

  55. INSPECT NO. 2 CLUTCH DISC

    A01GN3S

    1. Replace all No. 2 clutch discs if one of the following problems is present: 1) a No. 2 clutch disc, No. 2 clutch plate or No. 2 clutch flange is worn or burnt; 2) the lining of a No. 2 clutch disc is peeled off or discolored; or 3) the grooves or printed numbers have even a little bit of damage.

      Note

      Before assembling new No. 2 clutch discs, soak them in ATF for at least 2 hours.

  56. REMOVE DIRECT CLUTCH PISTON

    A01GHW9E01

    1. Place SST on the No. 2 clutch balancer and compress the direct clutch return spring with a press.

      SST
      09387-00020

    2. Using SST, remove the snap ring.

      SST
      09350-30020   ( 09350-07070 )
    3. A01GKQD

      Remove the No. 2 clutch balancer and direct clutch return spring sub-assembly from the direct clutch drum sub-assembly.

    4. Remove the O-ring from the No. 2 clutch balancer.

    5. A01GI84E02
      Text in Illustration
      *1 Oil Hole

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

    6. Remove the O-ring from the direct clutch piston.

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

  57. INSPECT DIRECT CLUTCH RETURN SPRING SUB-ASSEMBLY

    A01GJK4

    1. Using a vernier caliper, measure the free length of the direct clutch return spring sub-assembly together with the spring seat.

      Standard free length
      20.76 mm (0.817 in.)

      If the free length is shorter than the standard free length, replace the direct clutch return spring sub-assembly.

  58. REMOVE TRANSFER CASE ADAPTER REAR OIL SEAL

    A01GIGRE01
    Text in Illustration
    *1 Protective Tape

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

      Note

      Do not damage the surface of the oil seal press fit hole.

      Tech Tips

      Tape the screwdriver tip before use.

  59. REMOVE OUTPUT SHAFT REAR RADIAL BALL BEARING


    1. Using snap ring pliers, remove the snap ring from the transmission case.

    2. A01GNR2E01

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

      SST
      09308-00010

  60. REMOVE NO. 2 BRAKE PISTON

    A01GJPXE01

    1. 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

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

      SST
      09350-30020   ( 09350-07070 )
    3. A01GMZ9E03
      Text in Illustration
      *1 Oil Hole

      Hold the No. 2 brake piston and apply compressed air to the oil hole of the transmission case to remove the No. 2 brake piston.

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

  61. INSPECT NO. 2 BRAKE PISTON RETURN SPRING SUB-ASSEMBLY

    A01GLA5

    1. Using a vernier caliper, measure the free length of the No. 2 brake piston return spring sub-assembly together with the spring seat.

      Standard free length
      23.36 mm (0.920 in.)

      If the free length is shorter than the standard free length, replace the No. 2 brake piston return spring sub-assembly.