AUTOMATIC TRANSMISSION UNIT DISASSEMBLY

PROCEDURE


  1. REMOVE TRANSMISSION CONTROL SHAFT LEVER RH


    1. A001CDF

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

  2. REMOVE PARK/NEUTRAL POSITION SWITCH ASSEMBLY

    A001DWL

    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

    A001ERR

    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

    A001ESS

  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. A001DU7

      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

    A001CBE

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

    2. A001BFB

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

  7. REMOVE TRANSMISSION VALVE BODY ASSEMBLY


    1. A001F6S

      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. A001EH1

      Remove the bolt, detent spring cover and detent spring.

    5. A001AVI

      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

    A001B0D

    1. Remove the check ball body and spring.

  9. REMOVE TRANSMISSION WIRE

    A001BU7

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

    2. A001AJX

      Remove the bolt and pull out the transmission wire.

  10. REMOVE SPEED SENSOR

    A001EU1E05

    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

    A001CRN

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

  12. REMOVE PARKING LOCK PAWL BRACKET

    A001BB7

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

  13. REMOVE PARKING LOCK ROD SUB-ASSEMBLY

    A001FFV

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

  14. REMOVE PARKING LOCK PAWL SHAFT

    A001DSR

    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

    A0019O1

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

    2. A001AKL

      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. A001A7VE01
      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

    A001ERX

    1. Remove the 11 bolts from the transmission case.

    2. A001BAS

      Pull out the oil pump assembly.

      Note

      Do not damage the oil pump assembly.

    3. A001FQQ

      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

    A001D4R

    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

    Click here

  21. REMOVE FRONT PLANETARY GEAR ASSEMBLY

    A001E5F

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

    2. A001AXJ

      Remove the 3 clutch drum oil seal rings.

    3. A001ENG

      Remove the planetary carrier thrust washer.

    4. A001A1R

      Remove the 2 clutch drum oil seal rings.

    5. A001B3V

      Remove the planetary sun gear.

  22. INSPECT FRONT PLANETARY GEAR ASSEMBLY

    Click here

  23. REMOVE OVERDRIVE CLUTCH DISC SET


    1. A001CV2E01
      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

    Click here

  25. REMOVE REVERSE CLUTCH DISC SET


    1. A00192EE01
      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

    Click here

  27. REMOVE REVERSE CLUTCH PISTON

    A001E29E01

    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. A001CLV

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

    4. A001FTOE01
      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

    Click here

  29. REMOVE REVERSE CLUTCH DRUM SUB-ASSEMBLY

    A001APC

    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

    A001ACCE01

    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. A001DEG

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

    4. A001BYOE01
      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

    Click here

  32. INSPECT OVERDRIVE DIRECT CLUTCH DRUM SUB-ASSEMBLY

    Click here

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

    A001BG3

    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. A001CDT

      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. A001CB8E01
      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

    Click here

  36. REMOVE FORWARD CLUTCH PISTON

    A001CPJE01

    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. A001COZ

      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. A00190CE01
      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

    Click here

  38. INSPECT FORWARD CLUTCH DRUM SUB-ASSEMBLY

    Click here

  39. REMOVE MULTIPLE DISC CLUTCH CLUTCH HUB

    A001BEY

    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

    A001CAN

    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

    Click here

  42. REMOVE REAR PLANETARY SUN GEAR ASSEMBLY

    A0019SV

    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

    A001D4TE03

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

      SST
      09350-30020   ( 09350-07060 )
    2. A001D5X

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

  44. INSPECT REAR PLANETARY SUN GEAR ASSEMBLY

    Click here

  45. REMOVE REAR PLANETARY GEAR ASSEMBLY

    A001FO6

    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

    Click here

  47. REMOVE NO. 1 1-WAY CLUTCH

    A001CSE

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

  48. INSPECT REAR PLANETARY GEAR ASSEMBLY

    Click here

  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

    Click here

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

    A001FVD

    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. A001CMD

      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

    A001ERT

    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. A0019AQ

      Remove the 3 oil seal rings from the output shaft.

    3. A0019AV

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

  54. REMOVE NO. 2 CLUTCH DISC SET


    1. A001EW4E01
      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

    Click here

  56. REMOVE DIRECT CLUTCH PISTON

    A001B0HE01

    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. A001FUG

      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. A001CK2E02
      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

    Click here

  58. REMOVE TRANSFER CASE ADAPTER REAR OIL SEAL

    A001CW4E01
    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. A0019WCE02

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

      SST
      09308-00010

  60. REMOVE NO. 2 BRAKE PISTON

    A0019DFE02

    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. A001D0HE03
      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

    Click here