AUTOMATIC TRANSMISSION UNIT DISASSEMBLY


  1. REMOVE DRAIN PLUG


    1. Remove the drain plug and gasket.

  2. REMOVE BREATHER HOSE SUB-ASSEMBLY


    1. A003AVW

      Remove the bolt and clamp.

    2. Remove the breather hose sub-assembly.

    3. A003BZEE01
      Text in Illustration
      *1 No. 1 Breather Plug
      *2 Breather Hose
      *3 No. 2 Breather Plug

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

  3. REMOVE TRANSMISSION CONTROL SHAFT LEVER LH


    1. A003CZP

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

  4. REMOVE WIRE HARNESS CLAMP BRACKET


    1. Remove the bolt and wire harness clamp bracket.

  5. REMOVE PARK/NEUTRAL POSITION SWITCH ASSEMBLY


    1. A003ERDE01

      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.

  6. REMOVE ATF TEMPERATURE SENSOR


    1. A003F3U

      Remove the bolt and ATF temperature sensor.

  7. REMOVE OIL COOLER TUBE UNION


    1. A003CVJ

      Remove the 2 oil cooler tube unions.

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

  8. REMOVE SPEED SENSOR


    1. A003E7X

      Remove the bolt and speed sensor NC0.

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

    3. A003F1X

      Remove the bolt and speed sensor SP2.

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

  9. REMOVE EXTENSION HOUSING REAR OIL SEAL


    1. A003GX7E01

      Using SST, remove the extension housing rear oil seal together with the dust seal and retainer.

      SST
      09308-10010

      Note

      Be careful not to damage the extension housing sub-assembly.

  10. REMOVE OIL PUMP ASSEMBLY


    1. A003HTU

      Remove the 7 bolts.

    2. A003DXME02

      Using SST, remove the oil pump assembly.

      SST
      09610-20012

      1. Grasp the front pump stator shaft assembly and pull the oil pump assembly from the transmission case.

        Note

        Do not damage the stator shaft assembly bushing surface.

    3. A003HI8

      Remove the bearing from the oil pump assembly.

    4. A003H74

      Remove the O-ring from the oil pump assembly.

  11. REMOVE AUTOMATIC TRANSMISSION HOUSING


    1. A003HU7

      Remove the 6 bolts and automatic transmission housing.

    2. A003D9Y

      Remove the O-ring from the overdrive case sub-assembly.

  12. REMOVE EXTENSION HOUSING SUB-ASSEMBLY


    1. A003E1H

      Remove the 6 bolts.

    2. Remove the extension housing sub-assembly and gasket.

  13. REMOVE EXTENSION HOUSING BUSH APPLY TUBE


    1. A003CPCE10
      Text in Illustration
      *1 Extension Housing Bush Apply Tube
      *2 Bush Apply Tube Gasket

      Remove the bush apply tube gasket and extension housing bush apply tube from the extension housing sub-assembly.

  14. REMOVE EXTENSION HOUSING DUST DEFLECTOR


    1. A003ANP

      Hold the extension housing sub-assembly in a vise between aluminum plates.

      Note

      Do not overtighten the vise.

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

  15. INSPECT EXTENSION HOUSING SUB-ASSEMBLY

    A003EUP

    1. Using a cylinder gauge, measure the inside diameter of the extension housing sub-assembly bush.

      Maximum inside diameter
      38.09 mm (1.50 in.)

      If the inside diameter is more than the maximum, replace the extension housing sub-assembly.

  16. REMOVE SENSOR ROTOR


    1. A003HQCE05
      Text in Illustration
      *1 Key
      *2 Sensor Rotor
      *3 Snap Ring

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

    2. Remove the sensor rotor and key.

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

  17. REMOVE TRANSMISSION CASE REAR COVER


    1. A003HY2E04
      Text in Illustration
      *1 Gasket
      *2 Transmission Case Rear Cover

      Remove the 3 screws.

    2. Remove the transmission case rear cover and gasket.

  18. FIX TRANSMISSION CASE


    1. A003ETX

      Install the transmission case to an overhaul attachment.

  19. REMOVE AUTOMATIC TRANSMISSION OIL PAN SUB-ASSEMBLY

    Note

    Do not turn the transmission over as foreign matter in the bottom of the automatic transmission oil pan sub-assembly will contaminate the transmission valve body assembly.


    1. A003DBZ

      Remove the 14 bolts.

    2. Remove the automatic transmission oil pan sub-assembly and automatic transmission oil pan gasket from the transmission case.

    3. Remove the 2 transmission oil cleaner magnets from the automatic transmission oil pan sub-assembly.

  20. INSPECT AUTOMATIC TRANSMISSION OIL PAN SUB-ASSEMBLY


    1. Remove the 2 automatic transmission oil cleaner magnets and use them to collect steel particles. Carefully look at the foreign matter and particles in the automatic transmission oil pan sub-assembly and on the 2 automatic transmission oil cleaner magnets to determine the type of wear you will find in the automatic transmission assembly.

      Steel (magnetic): bearing, gear and clutch plate wear

      Brass (non-magnetic): bush wear

  21. REMOVE VALVE BODY OIL STRAINER ASSEMBLY


    1. A003GPO

      Remove the 3 bolts and valve body oil strainer assembly.

      Note

      Be careful as some fluid will leak out of the oil strainer.

    2. Remove the 3 gaskets from the valve body oil strainer assembly.

  22. REMOVE OVERDRIVE BRAKE TUBE


    1. A003CV1

      Pry out both ends of the overdrive brake tube with a large screwdriver and remove the overdrive brake tube.

      Note

      Be careful not to damage the input shaft sub-assembly.

      Tech Tips

      Tape the screwdriver tip before use.

  23. REMOVE TRANSMISSION WIRE


    1. A003BQQ

      Disconnect the 4 shift solenoid valve connectors.

    2. Remove the bolt and clamp.

    3. A003IA4

      Remove the bolt.

    4. Pull out the transmission wire from the transmission case to remove it.

    5. Remove the O-ring from the transmission wire.

  24. REMOVE TRANSMISSION VALVE BODY ASSEMBLY


    1. A003ES6

      Remove the 17 bolts and transmission valve body assembly.

  25. REMOVE ACCUMULATOR PISTON AND SPRING


    1. A003AFHE03
      Text in Illustration
      *1 C-1 Accumulator Piston
      *2 C-2 Accumulator Piston
      *3 B-2 Accumulator Piston

      Position a cloth to catch each piston.

    2. Apply compressed air to the oil holes shown in the illustration and remove the 3 accumulator pistons and 3 springs.

    3. Remove the 2 O-rings from each piston.

  26. REMOVE PARKING LOCK PAWL BRACKET


    1. A003BOA

      Remove the 2 bolts, 2 washers and parking lock pawl bracket.

  27. REMOVE PARKING LOCK ROD SUB-ASSEMBLY


    1. A003DTL

      Disconnect the parking lock rod sub-assembly from the manual valve lever and remove it.

  28. REMOVE PARKING LOCK PAWL SHAFT


    1. A003DM2E04
      Text in Illustration
      *1 Parking Lock Pawl Shaft
      *2 E-ring
      *3 Parking Lock Pawl
      *4 Spring

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

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

  29. REMOVE MANUAL VALVE LEVER SHAFT


    1. A003I7HE04
      Text in Illustration
      *a Protective Tape

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

      Note

      Be careful not to damage the manual valve lever shaft.

      Tech Tips

      Wrap the tip of the screwdriver with protective tape.

    2. A003CKO

      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 out the manual valve lever shaft through the case to remove it, and then remove the manual valve lever.

  30. REMOVE MANUAL VALVE LEVER SHAFT OIL SEAL


    1. A003HG6E02
      Text in Illustration
      *a Protective Tape

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

      Note

      Be careful not to damage the transmission case.

      Tech Tips

      Wrap the tip of the screwdriver with protective tape.

  31. INSPECT INSTALLATION DISTANCE OF OVERDRIVE DIRECT CLUTCH


    1. A003DZCE02

      Place SST on the transmission case.

      SST
      09350-20015   ( 09370-12010 )

    2. Using a vernier caliper, measure the distance between the top of the overdrive direct clutch drum sub-assembly and SST.

      Tech Tips

      Make a note of the measurement for reference during reassembly.

  32. REMOVE OVERDRIVE PLANETARY GEAR ASSEMBLY WITH OVERDRIVE DIRECT CLUTCH DRUM SUB-ASSEMBLY


    1. A003DYP

      Remove the overdrive planetary gear assembly together with the overdrive direct clutch drum sub-assembly from the transmission case.

    2. A003G79E03
      Text in Illustration
      *1 Race
      *2 Thrust Washer

      Remove the race and thrust washer.

  33. INSPECT OVERDRIVE ONE-WAY CLUTCH


    1. A003FUW

      Hold the overdrive direct clutch drum sub-assembly and turn the overdrive planetary gear assembly. Check that the overdrive planetary gear assembly can be turned clockwise but cannot be turned counterclockwise.

      Text in Illustration
      A003DCD Lock
      A003GWQ Free

  34. REMOVE OVERDRIVE DIRECT CLUTCH DRUM


    1. A003B23

      Remove the overdrive direct clutch drum from the overdrive planetary gear assembly.

  35. INSPECT OVERDRIVE DIRECT CLUTCH PISTON

    A003B98

    1. Place the overdrive direct clutch drum sub-assembly onto the oil pump assembly.

    2. A003HAX

      Using a dial indicator, measure the overdrive direct clutch piston sub-assembly stroke by applying and releasing compressed air (392 kPa (4.0 kgf/cm2, 57 psi)) as shown in the illustration.

      Standard piston stroke
      1.74 to 2.44 mm (0.0686 to 0.0960 in.)

      If the result is not as specified, inspect the overdrive clutch disc set.

    3. Remove the overdrive direct clutch drum sub-assembly from the oil pump assembly.

  36. REMOVE OVERDRIVE BRAKE HUB


    1. A003H5K

      Using a screwdriver, remove the snap ring.

      Note

      Be careful not to damage the overdrive direct clutch drum.

      Tech Tips

      Wrap the tip of the screwdriver with protective tape.

    2. Remove the overdrive brake hub.

  37. REMOVE OVERDRIVE CLUTCH DISC SET


    1. A003GZO

      Remove the overdrive clutch disc.

    2. A003EM2E03
      Text in Illustration
      *1 Snap Ring
      *2 Flange
      *3 Cushion Plate

      Using a screwdriver, remove the snap ring.

      Note

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

      Tech Tips

      Wrap the tip of the screwdriver with protective tape.

    3. Remove the flange and cushion plate.

  38. INSPECT OVERDRIVE CLUTCH DISC


    1. A003FK1

      Check whether the sliding surfaces of the overdrive clutch disc and overdrive clutch flange are worn or burnt.

      If necessary, replace the disc and flange.

      Note


      • If the lining of the overdrive clutch disc is peeled off or discolored, or if any part of the printed numbers are damaged, replace the disc.

      • Before assembling a new disc, soak it in ATF for at least 15 minutes.

  39. REMOVE OVERDRIVE CLUTCH RETURN SPRING SUB-ASSEMBLY


    1. A003FA9E02

      Place SST on the overdrive clutch return spring sub-assembly and compress the overdrive clutch return spring sub-assembly with a press.

      SST
      09350-20015   ( 09369-20040 )

    2. Using SST, remove the snap ring.

      SST
      09350-30020   ( 09350-07070 )

      Note

      Do not expand the snap ring excessively.

    3. A003DJY

      Remove the overdrive clutch return spring sub-assembly.

  40. REMOVE OVERDRIVE DIRECT CLUTCH PISTON


    1. A003DOG

      Place the overdrive direct clutch drum onto the oil pump assembly.

    2. Hold the overdrive direct clutch piston and apply compressed air to the oil pump assembly to remove the overdrive direct clutch piston.

    3. A003H61E02
      Text in Illustration
      *a Protective Tape

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

      Note

      Be careful not to damage the overdrive direct clutch piston.

      Tech Tips

      Wrap the tip of the screwdriver with protective tape.

  41. INSPECT OVERDRIVE DIRECT CLUTCH PISTON SUB-ASSEMBLY

    A003EK8

    1. Check that the check ball is free by shaking the overdrive direct clutch piston.

    2. Check that the valve does not have leaks by applying low-pressure compressed air.

  42. INSPECT OVERDRIVE DIRECT CLUTCH DRUM SUB-ASSEMBLY

    A003B8V

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

      Maximum inside diameter
      23.14 mm (0.911 in.)

      If the inside diameter is more than the maximum, replace the overdrive direct clutch drum sub-assembly.

  43. REMOVE OVERDRIVE ONE-WAY CLUTCH


    1. A003CP8E03
      Text in Illustration
      *a Protective Tape

      Using a screwdriver, remove the snap ring.

      Note

      Be careful not to damage the overdrive planetary gear assembly.

      Tech Tips

      Wrap the tip of the screwdriver with protective tape.

    2. A003ENCE04
      Text in Illustration
      *1 Thrust Washer
      *2 Overdrive One-way Clutch
      *3 Bearing

      Remove the 2 thrust washers, overdrive one-way clutch and bearing.

    3. A003DB0E02
      Text in Illustration
      *1 One-way Clutch Retainer
      *2 Overdrive One-way Clutch
      *3 Outer Race

      Remove the 2 one-way clutch retainers.

    4. Remove the overdrive one-way clutch from the outer race.

  44. INSPECT OVERDRIVE PLANETARY GEAR ASSEMBLY

    A003EP3E01

    1. Using a caliper gauge, measure the inside diameter of the overdrive planetary gear assembly bush.

      Maximum inside diameter
      11.27 mm (0.444 in.)

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

    2. A003BKK

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

      Standard clearance
      0.20 to 0.50 mm (0.00788 to 0.0196 in.)

      If the clearance is not as specified, inspect the planetary gear thrust washer. If necessary, replace the overdrive planetary gear assembly.

  45. INSPECT PISTON STROKE OF OVERDRIVE BRAKE PISTON

    A003CVS

    1. Place the overdrive case sub-assembly onto the transmission case with the cutout of the overdrive case sub-assembly facing downward.

      Tech Tips

      Make sure that the oil hole of the overdrive case sub-assembly is aligned with the oil hole of the transmission case.

    2. A003BPJ

      Using a dial indicator, measure the overdrive brake disc set pack clearance by applying and releasing compressed air (392 kPa (4.0 kgf/cm2, 57 psi)) as shown in the illustration.

      Standard pack clearance
      0.75 to 1.25 mm (0.0296 to 0.0492 in.)

      If the piston stroke is not as specified, parts may have been assembled incorrectly. Check the parts and reassemble again.

      Tech Tips


      • If the piston stroke is still not as specified, replace the plates with ones of a different thickness.

      • There are 2 types of plates that can be used to adjust the pack clearance. Select the one with the most appropriate thickness.

      Plate Thickness
      Part No. Thickness
      35634-30080 1.95 to 2.05 mm (0.0768 to 0.0807 in.)
      34634-30010 2.25 to 2.35 mm (0.0886 to 0.0925 in.)

    3. Remove the overdrive case sub-assembly from the transmission case.

  46. REMOVE OVERDRIVE CASE SUB-ASSEMBLY


    1. A003DG2

      Remove the overdrive case sub-assembly from the transmission case.

      Tech Tips

      When the overdrive brake is removed, the front clutch drum may adhere to it.

    2. A003C5QE03
      Text in Illustration
      *1 Thrust Washer
      *2 Race

      Remove the race and thrust washer.

    3. A003ATJ

      Remove the 2 oil seal rings.

  47. REMOVE OVERDRIVE BRAKE DISC SET


    1. Using a screwdriver, remove the snap ring.

      Note

      Be careful not to damage the overdrive case sub-assembly.

      Tech Tips

      Wrap the tip of the screwdriver with protective tape.

    2. Remove the flange, 3 overdrive brake discs and 3 plates.

  48. INSPECT OVERDRIVE BRAKE DISC

    A003G3N

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

      If necessary, replace the overdrive brake discs, plates and flange.

      Note


      • If the lining of an overdrive brake disc is peeled off or discolored, or if any part of the printed numbers are damaged, replace all the overdrive brake discs.

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

  49. REMOVE OVERDRIVE PLANETARY RING GEAR


    1. A003GPWE03
      Text in Illustration
      *1 Overdrive Planetary Ring Gear
      *2 Race
      *3 Bearing

      Remove the overdrive planetary ring gear.

    2. Remove the bearing and 2 races.

  50. REMOVE OVERDRIVE BRAKE RETURN SPRING SUB-ASSEMBLY


    1. A003FVUE01
      Text in Illustration
      *1 Snap Ring
      *2 Overdrive Brake Return Spring Sub-assembly

      Using a screwdriver, remove the snap ring.

      Note

      Be careful not to damage the overdrive case sub-assembly.

      Tech Tips

      Wrap the tip of the screwdriver with protective tape.

    2. Remove the overdrive brake return spring sub-assembly.

  51. REMOVE OVERDRIVE BRAKE PISTON


    1. A003G2LE01

      Hold the overdrive brake piston by hand and apply compressed air to the passage to remove the overdrive brake piston.

    2. Remove the 2 O-rings from the overdrive brake piston.

  52. INSPECT INSTALLATION DISTANCE OF FRONT CLUTCH ASSEMBLY


    1. A003G5LE01

      Place SST on the transmission case.

      SST
      09350-20015   ( 09370-12010 )

    2. Using a vernier caliper, measure the distance between the top of the front clutch drum and SST.

      Tech Tips

      Make a note of the measurement for reference during reassembly.

  53. REMOVE FRONT CLUTCH DRUM


    1. A003AJX

      Remove the front clutch drum from the transmission case.

    2. A003BOQE03
      Text in Illustration
      *1 Bearing
      *2 Race

      Remove the 2 bearings and race.

  54. REMOVE REAR CLUTCH HUB AND FRONT CLUTCH HUB


    1. A003FEX

      Place the front clutch drum onto the overdrive case sub-assembly.

    2. A003FTZE03
      Text in Illustration
      *1 Snap Ring
      *2 Rear Clutch Hub
      *3 Front Clutch Hub

      Using a screwdriver, remove the snap ring.

      Note

      Be careful not to damage the front clutch drum.

      Tech Tips

      Wrap the tip of the screwdriver with protective tape.

    3. Remove the rear clutch hub and front clutch hub.

    4. A003CYZE02
      Text in Illustration
      *1 Race
      *2 Bearing

      Remove the bearing and 2 races.

  55. INSPECT PISTON STROKE OF FRONT CLUTCH PISTON SUB-ASSEMBLY

    A003BVI

    1. In order to check the piston stroke, install the rear clutch hub.

    2. Install the snap ring.

    3. A003DV5E01

      Using SST and a dial indicator, measure the front clutch piston sub-assembly stroke by applying and releasing compressed air (392 kPa (4.0 kgf/cm2, 57 psi)) as shown in the illustration.

      SST
      09350-20015   ( 09350-06120 )
      Standard piston stroke
      1.40 to 1.60 mm (0.0552 to 0.0629 in.)

      If the piston stroke is not as specified, parts may have been assembled incorrectly. Check the parts and reassemble again.

      Tech Tips


      • If the piston stroke is still not as specified, replace the plates with ones of a different thickness.

      • There are 2 types of plates that can be used to adjust the pack clearance. Select the one with the most appropriate thickness.

        Plate Thickness
        Part No. Thickness
        35634-22040 1.75 to 1.85 mm (0.0689 to 0.0728 in.)
        34634-30070 1.95 to 2.05 mm (0.0768 to 0.0807 in.)

  56. REMOVE FRONT CLUTCH DISC SET


    1. A003GV5E03
      Text in Illustration
      *1 Front Clutch Disc
      *2 Snap Ring

      Remove the front clutch disc.

    2. Using a screwdriver, remove the snap ring.

      Note

      Be careful not to damage the front clutch drum.

      Tech Tips

      Wrap the tip of the screwdriver with protective tape.

    3. Remove the 4 plates and 3 front clutch discs.

  57. INSPECT FRONT CLUTCH DISC

    A003BG9

    1. Check whether the sliding surfaces of the front clutch discs and plates are worn or burnt.

      If necessary, replace them.

      Note


      • If the lining of a disc is peeled off or discolored, or if any part of the printed numbers are damaged, replace all the front clutch discs.

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

  58. REMOVE FRONT CLUTCH RETURN SPRING SUB-ASSEMBLY


    1. A003F7XE01

      Place SST on the front clutch return spring sub-assembly and compress the front clutch return spring sub-assembly with a press.

      SST
      09350-20015   ( 09369-20040 )

    2. Using SST, remove the snap ring.

      SST
      09350-30020   ( 09350-07070 )

      Note

      Do not expand the snap ring excessively.

    3. A003FSA

      Remove the front clutch return spring sub-assembly.

  59. REMOVE FRONT CLUTCH PISTON SUB-ASSEMBLY


    1. A003HBU

      Hold the front clutch piston sub-assembly by hand, apply compressed air to the overdrive case sub-assembly and remove the front clutch piston sub-assembly.

    2. A003H61E02
      Text in Illustration
      *a Protective Tape

      Remove the 2 O-rings from the front clutch piston sub-assembly.

      Note

      Be careful not to damage the front clutch piston sub-assembly.

      Tech Tips

      Wrap the tip of the screwdriver with protective tape.

  60. INSPECT FRONT CLUTCH PISTON SUB-ASSEMBLY

    A003GV4

    1. Check that the check ball is free by shaking the front clutch piston sub-assembly.

    2. Check that the valve does not have leaks by applying low-pressure compressed air.

  61. REMOVE REAR CLUTCH DRUM


    1. A003H3I

      Remove the rear clutch drum from the transmission case.

    2. A003EL7

      Remove the race.

  62. INSPECT PISTON STROKE OF REAR CLUTCH PISTON SUB-ASSEMBLY

    A003GAR

    1. Place the rear clutch drum onto the center support sub-assembly.

    2. A003HA7

      Using a dial indicator, measure the rear clutch piston stroke by applying and releasing compressed air (392 kPa (4.0 kgf/cm2, 57 psi)) as shown in the illustration.

      Standard piston stroke
      0.90 to 1.30 mm (0.0355 to 0.0511 in.)

      If the piston stroke is not as specified, parts may have been assembled incorrectly. Check the parts and reassemble again.

      Tech Tips


      • If the piston stroke is still not as specified, replace the flange with one of a different thickness.

      • There are 3 types of flanges that can be used to adjust the pack clearance. Select the one with the most appropriate thickness.

        Flange Thickness
        Part No. Mark Thickness
        35675-22120 A 3.475 to 3.600 mm (0.137 to 0.141 in.)
        35675-22130 B 3.675 to 3.800 mm (0.145 to 0.149 in.)
        35675-22140 - 3.925 to 4.050 mm (0.155 to 0.159 in.)

  63. REMOVE REAR CLUTCH DISC SET


    1. A003CF4

      Using a screwdriver, remove the snap ring.

      Note

      Be careful not to damage the rear clutch drum.

      Tech Tips

      Wrap the tip of the screwdriver with protective tape.

    2. Remove the flange, 3 rear clutch discs and 3 plates.

  64. INSPECT REAR CLUTCH DISC

    A003BG9

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

      If necessary, replace them.

      Note


      • If the lining of a rear clutch disc is peeled off or discolored, or if any part of the printed numbers are damaged, replace all the rear clutch discs.

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

  65. REMOVE REAR CLUTCH RETURN SPRING SUB-ASSEMBLY


    1. A003D2OE03

      Place SST on the rear clutch return spring sub-assembly and compress the rear clutch return spring sub-assembly with a press.

      SST
      09350-20015   ( 09369-20040 )

    2. Using SST, remove the snap ring.

      SST
      09350-30020   ( 09350-07070 )

      Note

      Do not expand the snap ring excessively.

    3. A003D9X

      Remove the rear clutch return spring sub-assembly.

  66. REMOVE CENTER SUPPORT SUB-ASSEMBLY

    A003H91

    1. Remove the 2 bolts and 2 washers.

      Tech Tips

      After removing one bolt, the other will be loose.

    2. A003G91

      Remove the center support sub-assembly from the transmission case.

    3. A003H9E

      Remove the 3 oil seal rings.

  67. REMOVE PLANETARY SUN GEAR SUB-ASSEMBLY WITH NO. 1 ONE-WAY CLUTCH


    1. A003HAR

      Using SST, remove the snap ring.

      SST
      09350-30020   ( 09350-07070 )

      Note

      Do not expand the snap ring excessively.

    2. A003DD0

      Remove the planetary sun gear sub-assembly with No. 1 one-way clutch.

  68. INSPECT PISTON STROKE OF NO. 1 BRAKE


    1. A003FKU

      Using a dial indicator, measure the No. 1 brake piston stroke by applying and releasing compressed air (392 kPa (4.0 kgf/cm2, 57 psi)) as shown in the illustration.

      Standard piston stroke
      0.75 to 1.35 mm (0.0296 to 0.0531 in.)

      If the stroke is not as specified, inspect the No. 1 brake discs.

  69. REMOVE NO. 1 BRAKE DISC SET


    1. A003BG8

      Using a screwdriver, remove the snap ring.

      Note

      Be careful not to damage the center support.

      Tech Tips

      Wrap the tip of the screwdriver with protective tape.

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

  70. INSPECT NO. 1 BRAKE DISC

    A003BW4

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

      If necessary, replace them.

      Note


      • If the lining of a No. 1 brake disc is peeled off or discolored, or if any part of the printed numbers are damaged, replace all the No. 1 brake discs.

      • Before assembling new No. 1 brake discs, soak them in ATF for at least 15 minutes.

  71. REMOVE NO. 1 BRAKE PISTON RETURN SPRING SUB-ASSEMBLY


    1. A003BHLE03

      Place SST on the No. 1 brake piston return spring sub-assembly and compress the No. 1 brake piston return spring sub-assembly with a press.

      SST
      09350-20015   ( 09369-20040 )

    2. Using SST, remove the snap ring.

      SST
      09350-30020   ( 09350-07070 )

      Note

      Do not expand the snap ring excessively.

    3. A003FZ9

      Remove the No. 1 brake piston return spring sub-assembly.

  72. REMOVE NO. 1 BRAKE PISTON


    1. A003GPYE01

      Hold the No. 1 brake piston by hand and apply compressed air to the center support sub-assembly to remove the brake piston.

    2. A003I4RE02
      Text in Illustration
      *a Protective Tape

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

      Note

      Be careful not to damage the No. 1 brake piston.

      Tech Tips

      Wrap the tip of the screwdriver with protective tape.

  73. INSPECT CENTER SUPPORT SUB-ASSEMBLY

    A003EMU

    1. Using a caliper gauge, measure the inside diameter of the center support sub-assembly bush.

      Maximum inside diameter
      36.41 mm (1.43 in.)

      If the inside diameter is more than the maximum, replace the center support sub-assembly.

  74. INSPECT PISTON STROKE OF NO. 2 BRAKE PISTON

    A003FMH

    1. Using a dial indicator, measure the No. 2 brake piston stroke by applying and releasing compressed air (392 kPa (4.0 kgf/cm2, 57 psi)) as shown in the illustration.

      Standard piston stroke
      0.98 to 1.71 mm (0.0386 to 0.0673 in.)

      If the stroke is not as specified, inspect the No. 2 brake discs.

  75. REMOVE NO. 2 BRAKE DISC SET


    1. A003HL8

      Using a screwdriver, remove the snap ring.

      Note

      Be careful not to damage the center support.

      Tech Tips

      Wrap the tip of the screwdriver with protective tape.

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

  76. INSPECT NO. 2 BRAKE DISC

    A003F0U

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

      If necessary, replace them.

      Note


      • If the lining of a No. 2 brake disc is peeled off or discolored, or if any part of the printed numbers are damaged, replace all the No. 2 brake discs.

      • Before assembling new No. 2 brake discs, soak them in ATF for at least 15 minutes.

  77. REMOVE NO. 2 BRAKE PISTON RETURN SPRING SUB-ASSEMBLY

    A003D8AE02

    1. Place SST on the No. 2 brake piston return spring sub-assembly and compress the No. 2 brake piston return spring sub-assembly with a press.

      SST
      09350-20015   ( 09369-20040 )

    2. Using SST, remove the snap ring.

      SST
      09350-30020   ( 09350-07070 )

      Note

      Do not expand the snap ring excessively.

    3. A003F83

      Remove the No. 2 brake piston return spring sub-assembly.

  78. REMOVE NO. 2 BRAKE PISTON


    1. A003ALZ

      Hold the No. 2 brake piston by hand, apply compressed air to the center support sub-assembly and remove the No. 2 brake piston.

    2. Using a screwdriver, remove the 2 O-rings from the No. 2 brake piston and center support sub-assembly.

      Note

      Be careful not to damage the No. 2 brake piston and center support sub-assembly.

      Tech Tips

      Wrap the tip of the screwdriver with protective tape.

  79. REMOVE REAR CLUTCH PISTON


    1. A003AVM

      Place the rear clutch drum onto the center support sub-assembly.

    2. Hold the rear clutch piston by hand, apply compressed air to the center support sub-assembly and remove the rear clutch piston and rear No. 2 clutch piston.

    3. A003B2IE02
      Text in Illustration
      *a Protective Tape

      Remove the 4 O-rings from the rear clutch piston and rear No. 2 clutch piston.

      Note

      Be careful not to damage the rear clutch piston and rear No. 2 clutch piston.

      Tech Tips

      Wrap the tip of the screwdriver with protective tape.

  80. INSPECT REAR CLUTCH PISTON

    A003GV4

    1. Check that the check ball is free by shaking the rear clutch piston sub-assembly.

    2. Check that the valve does not have leaks by applying low-pressure compressed air.

  81. INSPECT NO. 1 ONE-WAY CLUTCH ASSEMBLY


    1. A003GTB

      Hold the No. 1 one-way clutch and turn the planetary sun gear sub-assembly. Check that the planetary sun gear sub-assembly can be turned counterclockwise but cannot be turned clockwise.

      Text in Illustration
      A003DCD Lock
      A003GWQ Free

  82. REMOVE NO. 1 ONE-WAY CLUTCH


    1. A003B3G

      Remove the No. 1 one-way clutch from the planetary sun gear sub-assembly.

    2. A003GPKE01
      Text in Illustration
      *a Protective Tape

      Using a screwdriver, loosen the staked parts of the 2 one-way clutch retainers.

      Note

      Be careful not to damage the one-way clutch assembly.

      Tech Tips

      Wrap the tip of the screwdriver with protective tape.

    3. A003IC6E04
      Text in Illustration
      *1 One-way Clutch Retainer
      *2 No. 1 One-way Clutch
      *3 Outer Race

      Remove the No. 1 one-way clutch and 2 one-way clutch retainers from the outer race.

    4. A003D77

      Remove the 2 oil seal rings.

  83. INSPECT PLANETARY SUN GEAR SUB-ASSEMBLY

    A003FO3

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

      Maximum inside diameter
      21.53 mm (0.848 in.)

      If the inside diameter is more than the maximum, replace the planetary sun gear sub-assembly.

  84. REMOVE FRONT PLANETARY GEAR SUB-ASSEMBLY


    1. A003HBYE02
      Text in Illustration
      *a Protective Tape

      Using 2 screwdrivers, remove the snap ring.

      Note

      Be careful not to damage the automatic transmission case.

      Tech Tips

      Wrap the tip of the screwdriver with protective tape.

    2. A003I72

      Insert 2 wires into the front planetary gear sub-assembly and remove it.

    3. A003FN1

      Remove the thrust washer.

  85. INSPECT NO. 2 ONE-WAY CLUTCH


    1. A003FR6

      Hold the No. 2 one-way clutch inner race sub-assembly and turn the front planetary gear sub-assembly. Check that the front planetary gear sub-assembly can be turned counterclockwise but cannot be turned clockwise.

      Text in Illustration
      A003DCD Lock
      A003GWQ Free

  86. REMOVE NO. 2 ONE-WAY CLUTCH INNER RACE SUB-ASSEMBLY

    A003FCT

  87. REMOVE NO. 2 ONE-WAY CLUTCH


    1. A003DL5

      Using a screwdriver, remove the snap ring.

      Note

      Be careful not to damage the front planetary gear sub-assembly.

      Tech Tips

      Wrap the tip of the screwdriver with protective tape.

    2. A003HW9E01
      Text in Illustration
      *1 One-way Clutch Retainer
      *2 No. 2 One-way Clutch

      Remove the No. 2 one-way clutch and 2 one-way clutch retainers from the front planetary gear sub-assembly.

    3. A003EUK

      Remove the thrust washer.

  88. INSPECT FRONT PLANETARY GEAR SUB-ASSEMBLY

    A003CFJ

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

      Standard clearance
      0.20 to 0.50 mm (0.00788 to 0.0196 in.)

      If the clearance is not as specified, inspect the planetary gear thrust washer. If necessary, replace the front planetary gear sub-assembly.

  89. INSPECT PACK CLEARANCE OF NO. 3 BRAKE


    1. A003FV0

      Using a vernier caliper, measure the clearance between the No. 3 brake disc and transmission case as shown in the illustration.

      Standard pack clearance
      0.52 to 1.27 mm (0.0205 to 0.0499 in.)

      Tech Tips


      • If the result is not as specified, replace the pressure plate with one of a different thickness.

      • There are 6 types of pressure plates that can be used to adjust the pack clearance. Select the one with the most appropriate thickness.

      Pressure Plate Thickness
      Part No. Mark Thickness
      35639-22010 - 2.95 to 3.05 mm (0.117 to 0.120 in.)
      35639-22020 325 3.20 to 3.30 mm (0.126 to 0.129 in.)
      35639-22030 350 3.45 to 3.55 mm (0.136 to 0.139 in.)
      35639-22040 375 3.70 to 3.80 mm (0.146 to 0.149 in.)
      35639-22050 400 3.95 to 4.05 mm (0.156 to 0.159 in.)
      35639-22060 425 4.20 to 4.30 mm (0.166 to 0.169 in.)

  90. REMOVE NO. 3 BRAKE DISC SET


    1. Remove the 5 No. 3 brake discs, 4 plates and pressure plate.

  91. INSPECT NO. 3 BRAKE DISC

    A003ICJ

    1. Check whether the sliding surfaces of the No. 3 brake discs and plates are worn or burnt.

      If necessary, replace them.

      Note


      • If the lining of a No. 3 brake disc is peeled off or discolored, or if any part of the printed numbers are damaged, replace all the No. 3 brake discs.

      • Before assembling new No. 3 brake discs, soak them in ATF for at least 15 minutes.

  92. REMOVE INTERMEDIATE SHAFT SUB-ASSEMBLY WITH REAR PLANETARY GEAR ASSEMBLY AND OUTPUT SHAFT ASSEMBLY


    1. A003D78

      Remove the intermediate shaft sub-assembly with rear planetary gear assembly and output shaft assembly from the transmission case.

    2. A003CLL

      Remove the bearing.

    3. A003EPP

      Remove the thrust washer.

  93. REMOVE FRONT PLANETARY RING GEAR


    1. A003G7K

      Using a snap ring expander, remove the front planetary ring gear while compressing the snap ring.

    2. A003E3U

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

      Note


      • Be careful not to damage the front planetary ring gear.

      • Do not expand the snap ring excessively.

      Tech Tips

      Wrap the tip of the screwdriver with protective tape.

    3. A003BCA

      Remove the oil seal ring.

  94. REMOVE INTERMEDIATE SHAFT SUB-ASSEMBLY WITH REAR PLANETARY GEAR ASSEMBLY AND REAR PLANETARY RING GEAR SUB-ASSEMBLY


    1. A003H7A

      Remove the intermediate shaft sub-assembly with rear planetary gear assembly and rear planetary ring gear sub-assembly from the output shaft assembly.

    2. A003FA1E02
      Text in Illustration
      *1 Race
      *2 Bearing

      Remove the bearing and race.

  95. INSPECT OUTPUT SHAFT ASSEMBLY

    A003HBB

    1. Using a caliper gauge, measure the inside diameter of the output shaft assembly bush.

      Maximum inside diameter
      18.03 mm (0.710 in.)

      If the inside diameter is more than the maximum, replace the output shaft assembly.

  96. REMOVE REAR PLANETARY GEAR ASSEMBLY

    A003EZO

  97. INSPECT REAR PLANETARY GEAR ASSEMBLY

    A003END

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

      Standard clearance
      0.20 to 0.50 mm (0.00788 to 0.0196 in.)

      If the clearance is not as specified, inspect the planetary gear thrust washer. If necessary, replace the rear planetary gear assembly.

  98. REMOVE REAR PLANETARY SUN GEAR

    A003DSF

  99. REMOVE REAR PLANETARY RING GEAR SUB-ASSEMBLY


    1. A003DVT

      Using a screwdriver, remove the set ring.

    2. A003C56

      Remove the rear planetary ring gear sub-assembly.

    3. A003C5G

      Remove the bearing from the rear planetary ring gear sub-assembly.

    4. A003CQ2

      Using a screwdriver, remove the oil seal ring.

      Note

      Be careful not to damage the intermediate shaft sub-assembly.

      Tech Tips

      Wrap the tip of the screwdriver with protective tape.

  100. REMOVE BRAKE APPLY TUBE


    1. A003H3X

      Remove the brake apply tube.

    2. A003H50

      Remove the race from the transmission case.

  101. REMOVE BRAKE PLATE STOPPER SPRING

    A003DS8

  102. INSPECT NO. 3 BRAKE PISTON MOVEMENT

    A003EX5

    1. Check that the No. 3 brake pistons move smoothly when applying compressed air into and releasing compressed air from the transmission case.

  103. REMOVE NO. 3 BRAKE PISTON RETURN SPRING SUB-ASSEMBLY


    1. A003B8YE03
      Text in Illustration
      *1 Snap Ring

      Set SST on the No. 3 brake piston return spring sub-assembly and compress the No. 3 brake piston return spring sub-assembly.

      SST
      09350-20015   ( 09369-20040 )

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

      Note

      Do not expand the snap ring excessively.

    3. A003AKN

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

  104. REMOVE NO. 3 BRAKE PISTON

    A003EG6

    1. While holding the No. 3 brake piston by hand, apply compressed air to the transmission case and then remove the No. 3 brake piston.

      If the No. 3 brake piston does not pop out with compressed air, lift the No. 3 brake piston out with needle-nose pliers.

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

    3. A003FKFE04

      Insert SST behind the brake reaction sleeve and gradually lift it out of the transmission case to remove the brake reaction sleeve.

      SST
      09350-30020   ( 09350-07080 )

    4. Remove the 2 O-rings from the brake reaction sleeve.

    5. A003EV3E04

      Insert SST behind the inner piston and gradually lift it out of the transmission case to remove the inner piston.

      SST
      09350-30020   ( 09350-07090 )

    6. Remove the 2 O-rings from the inner piston.

  105. INSPECT TRANSMISSION CASE

    A003BN1

    1. Using a cylinder gauge, measure the inside diameter of the transmission case bush.

      Maximum inside diameter
      38.19 mm (1.50 in.)

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