AUTOMATIC TRANSMISSION UNIT (for 1KD-FTV) DISASSEMBLY


  1. REMOVE TRANSMISSION CONTROL SHAFT LEVER LH


    1. A003ID7E01

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

  2. REMOVE PARK/NEUTRAL POSITION SWITCH ASSEMBLY


    1. A003GXS

      Using a screwdriver, unstake the lock washer.

    2. Remove the nut and the lock washer.

    3. A003E7B

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

      Tech Tips

      Make sure that the manual valve lever shaft has not been rotated prior to installing the park/neutral position switch as the detent spring may become detached from the manual valve lever shaft.

  3. REMOVE TEMPERATURE SENSOR (w/ DPF)

    A003BLB

    1. Detach the temperature sensor connector clamp from the wire harness bracket.

    2. Using a 19 mm union nut wrench, remove the temperature sensor from the automatic transmission assembly.

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

  4. REMOVE TEMPERATURE SENSOR (w/o DPF)


    1. A003BZBE01

      Remove the temperature sensor.

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

  5. REMOVE OIL COOLER TUBE UNION

    A003EGPE01

    1. Remove the 2 oil cooler tube unions.

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

  6. REMOVE BREATHER HOSE


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

  7. REMOVE SPEEDOMETER SENSOR (w/ Speedometer Sensor)


    1. A003F6BE01

      Remove the bolt and the speedometer sensor.

    2. A003FA2

      Remove the speedometer driven gear from the speedometer sensor.

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

  8. REMOVE SPEED SENSOR NC0


    1. A003GSJE01

      Remove the bolt and the speed sensor NC0.

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

  9. REMOVE SPEED SENSOR SP2


    1. A003D1FE01

      Remove the bolt and the speed sensor SP2.

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

  10. REMOVE AUTOMATIC TRANSMISSION HOUSING


    1. A003FFSE01

      Remove the 6 bolts.

    2. Remove the automatic transmission housing.

  11. FIX AUTOMATIC TRANSMISSION CASE SUB-ASSEMBLY


    1. A003HIT

      Install the automatic transmission case sub-assembly onto the overhaul attachment.

  12. REMOVE EXTENSION HOUSING SUB-ASSEMBLY


    1. A003E1H

      Remove the 6 bolts.

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

  13. REMOVE EXTENSION HOUSING BUSH APPLY TUBE GASKET


    1. A003CPCE06

      Remove the extension housing bush apply tube gasket.

  14. REMOVE EXTENSION HOUSING BUSH APPLY TUBE


    1. A003CPCE07

      Remove the extension housing bush apply tube.

  15. REMOVE AUTOMATIC TRANSMISSION EXTENSION HOUSING OIL SEAL


    1. A003G3WE01

      Using SST, remove the automatic transmission extension housing oil seal.

      SST
      09308-00010

  16. REMOVE EXTENSION HOUSING DUST DEFLECTOR


    1. A003ANP

      Mount the extension housing sub-assembly in a soft jaw vise.

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

  17. INSPECT EXTENSION HOUSING SUB-ASSEMBLY


    1. A003CTI

      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.

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


    1. A003FXNE01

      Using snap ring expander, remove the snap ring.

    2. Remove the speedometer drive gear and the ball.

  19. REMOVE SENSOR ROTOR (w/ Speedometer Sensor)


    1. A003CX1E04

      Remove the sensor rotor and the key.

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

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


    1. A003FC4E04

      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.

  21. REMOVE AUTOMATIC TRANSMISSION OIL PAN SUB-ASSEMBLY


    1. A003I03E01

      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 automatic transmission oil pan sub-assembly.

    2. A003FPQE04

      Insert the blade of an oil pan seal cutter between the transmission case and automatic transmission oil pan sub-assembly, and then cut through the applied sealer.

      Note

      Be careful not to damage the flanges of the automatic transmission oil pan sub-assembly and transmission case.

    3. Remove the automatic transmission oil pan sub-assembly by lifting the transmission case.

  22. INSPECT AUTOMATIC TRANSMISSION OIL PAN SUB-ASSEMBLY


    1. A003C9I

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

      Carefully look 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. A003HOV

      Remove the 4 bolts.

    2. Remove the valve body oil strainer assembly and the 5 gaskets.

  24. REMOVE TRANSMISSION WIRE


    1. A003B7Q

      Disconnect the 4 connectors from each shift solenoid valve.

    2. A003E1RE03

      Remove the bolt.

    3. Pull out the transmission wire from the automatic transmission case sub-assembly.

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

  25. REMOVE TRANSMISSION VALVE BODY ASSEMBLY


    1. A003I22E01

      Remove the 20 bolts and the transmission valve body assembly.

  26. REMOVE CHECK BALL BODY


    1. A003I3GE02

      Remove the check ball body and the spring.

  27. REMOVE B-2 ACCUMULATOR PISTON


    1. A003E5G

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

      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 the compressed air.

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

  28. REMOVE C-2 ACCUMULATOR PISTON


    1. A003E5G

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

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

  29. REMOVE B-0 ACCUMULATOR PISTON


    1. A003EJC

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

      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 2 O-rings from the B-0 accumulator piston.

  30. REMOVE C-0 ACCUMULATOR PISTON


    1. A003ESY

      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. A003BIP

      Remove the 3 bolts and the parking lock pawl bracket.

  32. REMOVE PARKING LOCK ROD SUB-ASSEMBLY


    1. A003AMI

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

  33. REMOVE PARKING LOCK PAWL SHAFT


    1. A003HDZE02

      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 parking lock pawl shaft.

  34. REMOVE MANUAL VALVE LEVER SUB-ASSEMBLY


    1. A003CP9E02

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

    2. A003E3N

      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 automatic transmission case sub-assembly, and remove the manual valve lever sub-assembly.

  35. REMOVE MANUAL VALVE LEVER SHAFT OIL SEAL


    1. A003C4L

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

  36. REMOVE FRONT OIL PUMP BODY SUB-ASSEMBLY


    1. A003BH8

      Stand up the transmission.

    2. Remove the 7 bolts.

    3. A003GNSE02

      Using SST, remove the front oil pump body sub-assembly.

      SST
      09350-30020   ( 09350-07020 )

    4. Remove the O-ring from the front oil pump body sub-assembly.

    5. A003GUTE02

      Remove the thrust bearing race from the front oil pump body sub-assembly.

  37. REMOVE OVERDRIVE PLANETARY GEAR ASSEMBLY


    1. A003FK2

      Remove the overdrive planetary gear, overdrive direct clutch and one-way clutch from the automatic transmission case sub-assembly.

    2. A003CWIE01

      Remove the thrust needle roller bearing and the thrust bearing race from overdrive planetary gear assembly.

  38. REMOVE OVERDRIVE PLANETARY RING GEAR


    1. A003FJ0

      Remove the overdrive planetary ring gear from the automatic transmission case sub-assembly.

    2. A003CQWE01

      Remove the thrust needle roller bearing and the thrust bearing race from the overdrive planetary ring gear.

  39. INSPECT OVERDRIVE BRAKE PISTON


    1. A003I0ZE02

      Place SST and a dial indicator onto the overdrive brake piston.

      SST
      09350-30020   ( 09350-06120 )
    2. A003B61

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

      Piston stroke
      1.40 to 1.70 mm (0.0551 to 0.0669 in.)

      If the piston stroke is less than the limit, parts may be assembled incorrectly, so check and reassemble them if necessary.

      If the piston stroke is still outside the specified range, select another flange.

      Tech Tips

      There are 7 different thicknesses for the flange.

      Flange thickness
      No. Thickness No. Thickness
      77 3.3 mm (0.130 in.) 81 3.8 mm (0.150 in.)
      78 3.5 mm (0.138 in.) 82 3.9 mm (0.154 in.)
      79 3.6 mm (0.142 in.) 83 4.0 mm (0.157 in.)
      80 3.7 mm (0.146 in.) - -

  40. REMOVE OVERDRIVE BRAKE PACK


    1. A003FH6E02

      Using a screwdriver, remove the snap ring.

      Tech Tips

      Tape up the screwdriver tip before use.

    2. A003AP8E01

      Remove the overdrive brake pack.

  41. INSPECT PISTON STROKE OF 2ND COAST BRAKE


    1. A003FAGE02

      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
      1.50 to 3.00 mm (0.0591 to 0.1181 in.)

      If the stroke is outside the specified range, replace the piston rod.

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

      If the stroke is still outside the specified range, replace the 2nd coast brake band assembly with a new one.

  42. INSPECT OUTPUT SHAFT


    1. A003DSC

      Using a dial indicator, measure the end play of the output shaft by hand.

      End play
      0.30 to 1.04 mm (0.0118 to 0.0409 in.)

      If the value is outside the standard range, check for improper installation.

    2. Check that the output shaft rotates smoothly.

  43. REMOVE OVERDRIVE SUPPORT SUB-ASSEMBLY


    1. A003ED4

      Remove the 2 bolts from the automatic transmission case sub-assembly.

    2. A003F0RE02

      Using SST, remove the snap ring.

      SST
      09350-30020   ( 09350-07020, 09350-07060 )
    3. A003FAIE02

      Using SST, remove the overdrive support sub-assembly.

      SST
      09350-30020   ( 09350-07020 )
    4. A003D2X

      Remove the clutch drum thrust washer from the overdrive support sub-assembly.

    5. A003HULE01

      Remove the thrust needle roller bearing and the thrust bearing race from the overdrive support sub-assembly.

  44. REMOVE 2ND COAST BRAKE PISTON


    1. A003H6CE02

      Using SST, remove the snap ring.

      SST
      09350-30020   ( 09350-07060 )
    2. A003AMC

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

    3. Remove the 2 O-rings from the 2nd coast brake cover.

  45. REMOVE DIRECT CLUTCH ASSEMBLY


    1. A003H0M

      Remove the direct clutch assembly with the forward clutch assembly from the automatic transmission case sub-assembly.

  46. REMOVE FORWARD CLUTCH ASSEMBLY


    1. A003GKYE01

      Remove the forward clutch assembly from the direct clutch assembly.

    2. A003F20E01

      Remove the No. 2 clutch drum thrust washer, thrust needle roller bearing and thrust bearing race from the forward clutch assembly.

  47. REMOVE 2ND COAST BRAKE BAND ASSEMBLY


    1. A003HMS

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

      Tech Tips

      Apply 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 2nd coast brake band assembly.

    3. Remove the E-ring from the pin.

    4. A003I6V

      Remove the 2nd coast brake band assembly from the automatic transmission case sub-assembly.

  48. REMOVE FRONT PLANETARY RING GEAR SUB-ASSEMBLY


    1. A003BKS

      Remove the front planetary ring gear sub-assembly from the automatic transmission case sub-assembly.

    2. A003BXAE01

      Remove the 2 thrust needle roller bearings and the thrust bearing race from the front planetary ring gear sub-assembly.

    3. A003DDG

      Remove the thrust bearing race from the front planetary gear assembly.

    4. A003AR6E02

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

  49. INSPECT FRONT PLANETARY RING GEAR SUB-ASSEMBLY


    1. A003E9O

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

      Maximum inside diameter
      24.02 mm (0.9457 in.)

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

  50. REMOVE FRONT PLANETARY GEAR ASSEMBLY


    1. A003CN1E01

      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. A003H8E

      Remove the front planetary gear assembly from the automatic transmission case sub-assembly.

    3. A003FAJE01

      Remove the thrust needle roller bearing and the thrust bearing race from the front planetary gear assembly.

      If necessary, using a screw driver.

  51. INSPECT PLANETARY PINION GEAR THRUST CLEARANCE


    1. A003CTJ

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

      Standard clearance
      0.20 to 0.60 mm (0.0079 to 0.0236 in.)
      Maximum clearance
      0.60 mm (0.0236 in.)

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

  52. REMOVE PLANETARY SUN GEAR SUB-ASSEMBLY


    1. A003FPRE03

      Remove the planetary sun gear sub-assembly and the 1 way clutch from the automatic transmission case sub-assembly.

    2. Remove the No. 4 planetary carrier thrust washer.

  53. REMOVE 1 WAY CLUTCH ASSEMBLY


    1. A003DB2

      Remove the 1 way clutch assembly from the planetary sun gear sub-assembly.

    2. A003DC9

      Remove the No. 2 planetary carrier thrust washer from the planetary sun gear sub-assembly.

  54. INSPECT 2ND BRAKE PACK CLEARANCE


    1. A003FL9

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

      Standard clearance
      0.62 to 1.98 mm (0.0244 to 0.0780 in.)

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

  55. REMOVE 2ND BRAKE PACK


    1. A003EYJE02

      Using a screwdriver, remove the snap ring.

      Tech Tips

      Tape up the screwdriver tip before use.

    2. A003BDLE05

      Remove the 2nd brake pack.

  56. INSPECT PACK CLEARANCE OF 1ST AND REVERSE BRAKE


    1. A003FHK

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

      Standard clearance
      0.70 to 1.22 mm (0.0276 to 0.0480 in.)

      If the clearance is outside the standard range, select another flange.

      Flange thickness
      No. Thickness No. Thickness
      67 5.4 mm (0.213 in.) 52 4.6 mm (0.181 in.)
      66 5.2 mm (0.205 in.) 53 4.4 mm (0.173 in.)
      50 5.0 mm (0.197 in.) 54 4.2 mm (0.165 in.)
      51 4.8 mm (0.189 in.) 55 4.0 mm (0.157 in.)

  57. REMOVE 2ND BRAKE PISTON SLEEVE


    1. A003FP0

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

      Tech Tips

      Tape up the screwdriver tip before use.

  58. REMOVE REAR PLANETARY GEAR ASSEMBLY


    1. A003IF9E02

      Using SST and a screwdriver, remove the snap ring.

      SST
      09350-30020   ( 09350-07060 )
    2. A003D7R

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

    3. A003FPK

      Remove the 2nd brake piston assembly.

    4. A003FUB

      Remove the 1st and reverse brake pack.

    5. A003HDU

      Remove the leaf spring.

  59. INSPECT 1ST AND REVERSE BRAKE CLUTCH DISC


    1. A003E4XE02

      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.

  60. REMOVE BRAKE DRUM GASKET


    1. A003AFSE01

      Remove the brake drum gasket.

  61. INSPECT PISTON STROKE OF 1ST AND REVERSE BRAKE


    1. A003HR5

      Make sure that the No. 2 1st and reverse brake piston move smoothly when applying and releasing compressed air into the transmission case.

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


    1. A003DYR

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

    2. A003EAHE02

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

      SST
      09350-30020   ( 09350-07050 )

      Note

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

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

    4. Remove the 1st and reverse brake return spring sub-assembly.

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


    1. A003GO4E02

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

      Standard free length
      18.39 mm (0.7240 in.)

      If the free length is shorter than the standard free length, replace the 1st and reverse brake return spring sub-assembly.

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


    1. A003FX9

      Hold the No. 2 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 No. 2 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 No. 2 1st and reverse brake piston.

  65. REMOVE BRAKE REACTION SLEEVE


    1. A003D8XE02

      Install SST behind the brake reaction sleeve and gradually lift it out of the automatic transmission case sub-assembly.

      SST
      09350-30020   ( 09350-07080 )

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

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


    1. A003HWDE02

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

      SST
      09350-30020   ( 09350-07090 )

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

  67. INSPECT AUTOMATIC TRANSMISSION CASE SUB-ASSEMBLY


    1. A003F64

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

      Maximum inside diameter
      38.13 mm (1.5012 in.)

      If the inside diameter is greater than the maximum, replace the automatic transmission case sub-assembly.