AUTOMATIC TRANSMISSION UNIT DISASSEMBLY

PROCEDURE


  1. REMOVE TRANSMISSION BREATHER HOSE SUB-ASSEMBLY


    1. B001Z5V

      Remove the bolt and transmission breather hose sub-assembly from the automatic transmission case sub-assembly.

    2. B001YLWE01
      Text in Illustration
      *1 No. 2 Breather Plug
      *2 No. 1 Breather Plug
      *3 Breather Plug Hose
      *4 Clamp
      *5 Breather Plug O-ring

      Remove the clamp from the breather plug hose.

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

    4. Remove the breather plug O-ring from the No. 1 breather plug.

  2. REMOVE AUTOMATIC TRANSMISSION HOUSING


    1. B00203M

      Remove the 16 bolts and automatic transmission housing from the automatic transmission case sub-assembly.

  3. FIX AUTOMATIC TRANSMISSION ASSEMBLY


    1. B001WM8

      Install the automatic transmission assembly to an overhaul attachment.

  4. REMOVE REAR TRANSFER ADAPTER


    1. B001YNR

      Remove the 10 bolts.

    2. Remove the rear transfer adapter.

      Tech Tips

      Tap on the circumference of the rear transfer adapter with a plastic-faced hammer to remove the rear transfer adapter.

    3. Remove the O-ring from the rear transfer adapter.

  5. REMOVE TRANSFER CASE ADAPTER REAR OIL SEAL


    1. B001WOQE01
      Text in Illustration
      *a Protective Tape

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

      Note

      Be careful not to damage the rear transfer adapter.

      Tech Tips

      Tape the screwdriver tip before use.

  6. REMOVE PARK/NEUTRAL POSITION SWITCH ASSEMBLY

    Click here

  7. REMOVE OIL COOLER TUBE UNION


    1. B00201X

      Remove the 2 oil cooler tube unions from the automatic transmission case sub-assembly.

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

  8. REMOVE REFILL PLUG


    1. Remove the refill plug from the automatic transmission case sub-assembly.

    2. Remove the O-ring from the refill plug.

  9. REMOVE AUTOMATIC TRANSMISSION CASE PLUG


    1. for T55H "TORX" Type:


      1. B001XI6E01
        Text in Illustration
        *A for LH Side
        *B for Rear Side

        Using a T55H "TORX" socket wrench, remove the 2 automatic transmission case plugs from the automatic transmission case sub-assembly.

      2. Remove the 2 O-rings from the 2 automatic transmission case plugs.

    2. for 17 mm Hexagon Type:


      1. B001Z2X

        Remove the automatic transmission case plug from the automatic transmission case sub-assembly.

      2. Remove the O-ring from the automatic transmission case plug.

  10. REMOVE AUTOMATIC TRANSMISSION OIL PAN SUB-ASSEMBLY

    Click here

  11. REMOVE VALVE BODY OIL STRAINER ASSEMBLY

    Click here

  12. REMOVE TRANSMISSION VALVE BODY ASSEMBLY

    Click here

  13. REMOVE TRANSMISSION WIRE

    Click here

  14. REMOVE TRANSMISSION REVOLUTION SENSOR (SP2)

    Click here

  15. REMOVE PARKING LOCK PAWL BRACKET


    1. B001X3S

      Remove the 3 bolts and parking lock pawl bracket.

  16. REMOVE MANUAL VALVE LEVER SUB-ASSEMBLY


    1. B001Z2EE04
      Text in Illustration
      *a Protective Tape

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

      Note

      Be careful not to damage the manual valve lever sub-assembly.

      Tech Tips

      Tape the screwdriver tip before use.

    2. B001ZI4

      Using a 3 mm pin punch and a hammer, remove the spring pin.

      Tech Tips

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

    3. Remove the manual valve lever shaft and manual valve lever sub-assembly from the automatic transmission case sub-assembly.

  17. REMOVE PARKING LOCK ROD SUB-ASSEMBLY


    1. B001XKQE01
      Text in Illustration
      *1 Manual Valve Lever Sub-assembly
      *2 Parking Lock Rod Sub-assembly

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

  18. REMOVE PARKING LOCK PAWL SHAFT


    1. B001W0BE01
      Text in Illustration
      *1 Parking Lock Pawl
      *2 Parking Lock Pawl Shaft
      *3 Spring
      *4 E-ring

      Remove the parking lock pawl shaft, parking lock pawl and spring.

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

  19. REMOVE MANUAL VALVE LEVER SHAFT OIL SEAL


    1. B001VS9E04
      Text in Illustration
      *A for RH Side
      *B for LH Side
      *a Protective Tape

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

      Note

      Be careful not to damage the automatic transmission case sub-assembly.

      Tech Tips

      Tape the screwdriver tip before use.

  20. REMOVE MANUAL DETENT SPRING SUB-ASSEMBLY


    1. B001WU9E01
      Text in Illustration
      *1 Manual Detent Spring Sub-assembly
      *2 Manual Detent Spring Cover

      Remove the bolt, manual detent spring sub-assembly and manual detent spring cover.

  21. REMOVE OIL PUMP ASSEMBLY


    1. B001XUN

      Remove the 11 bolts from the oil pump assembly.

    2. B001XJP

      Pull out the oil pump assembly from the automatic transmission case sub-assembly.

      Note

      Do not damage the oil pump assembly.

    3. B001Z8PE05
      Text in Illustration
      *1 Oil Pump Assembly
      *2 Oil Pump O-ring

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

  22. REMOVE OVERDRIVE BRAKE PLATE STOPPER SPRING


    1. B001X3D

      Remove the overdrive brake plate stopper spring from the automatic transmission case sub-assembly.

  23. REMOVE OVERDRIVE AND REVERSE MULTIPLE DISC CLUTCH ASSEMBLY AND FRONT PLANETARY GEAR ASSEMBLY WITH NO. 1 BRAKE DISC SET


    1. B001XX6E01
      Text in Illustration
      *1 Overdrive and Reverse Multiple Disc Clutch Assembly and Front Planetary Gear Assembly with No. 1 Brake Disc Set
      *2 Thrust Needle Roller Bearing
      *3 Thrust Bearing Race

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

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

    3. Remove the snap ring from the automatic transmission case sub-assembly.

  24. REMOVE NO. 1 BRAKE DISC SET


    1. B001XNFE01
      Text in Illustration
      *1 No. 1 Brake Plate
      *2 No. 1 Brake Disc
      *3 No. 1 Brake Flange

      Remove the 6 No. 1 brake plates, 6 No. 1 brake discs and No. 1 brake flange.

  25. INSPECT NO. 1 BRAKE DISC

    Click here

  26. REMOVE FRONT PLANETARY GEAR ASSEMBLY


    1. B001YTWE01
      Text in Illustration
      *1 Front Planetary Gear Assembly

      Remove the front planetary gear assembly together with the planetary sun gear from the overdrive and reverse multiple disc clutch assembly.

    2. B001WS3E01
      Text in Illustration
      *1 Front Planetary Sun Gear

      Remove the front planetary sun gear from the front planetary gear assembly.

    3. B001X79E01
      Text in Illustration
      *1 Planetary Carrier Thrust Washer

      Remove the planetary carrier thrust washer from the front planetary gear assembly.

    4. B001VULE02
      Text in Illustration
      *1 Oil Seal Ring

      Remove the 3 oil seal rings from the front planetary gear assembly.

    5. B001VWCE05
      Text in Illustration
      *1 Oil Seal Ring

      Remove the 2 oil seal rings from the front planetary gear assembly.

    6. B001YEGE01
      Text in Illustration
      *1 Front Planetary Gear Radial Needle Roller Bearing

      Remove the front planetary gear radial needle roller bearing from the front planetary gear assembly.

  27. INSPECT FRONT PLANETARY GEAR ASSEMBLY

    Click here

  28. REMOVE NO. 3 CLUTCH DISC SET


    1. B001XG1E01
      Text in Illustration
      *a Protective Tape

      Using a screwdriver, remove the snap ring from the reverse clutch drum sub-assembly.

      Note

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

      Tech Tips

      Tape the screwdriver tip before use.

    2. B001X42E02
      Text in Illustration
      *1 No. 3 Clutch Flange
      *2 No. 3 Clutch Discs
      *3 No. 3 Clutch Plate

      Remove the No. 3 clutch flange, 6 No. 3 clutch discs and 6 No. 3 clutch plates from the reverse clutch drum sub-assembly.

  29. INSPECT NO. 3 CLUTCH DISC

    Click here

  30. REMOVE OVERDRIVE DIRECT CLUTCH DISC


    1. B001YIKE01
      Text in Illustration
      *a Protective Tape

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

      Note

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

      Tech Tips

      Tape the screwdriver tip before use.

    2. B001VVEE01
      Text in Illustration
      *1 Overdrive Clutch Flange
      *2 Overdrive Direct Clutch Disc
      *3 Overdrive Direct Clutch Plate

      Remove the overdrive clutch flange, 6 overdrive direct clutch discs and 6 overdrive direct clutch plates from the overdrive direct clutch drum sub-assembly.

  31. INSPECT OVERDRIVE DIRECT CLUTCH DISC

    Click here

  32. REMOVE NO. 4 CLUTCH PISTON


    1. B001Z1DE01

      Place SST on the reverse clutch balancer, and compress the reverse clutch return spring sub-assembly (rear) with a press.

      SST
      09380-50010   ( 09381-05020 )

    2. Using SST, remove the snap ring.

      SST
      09350-30020   ( 09350-07070 )
    3. B001WTRE01
      Text in Illustration
      *1 Reverse Clutch Balancer
      *2 Reverse Clutch Return Spring Sub-assembly (Rear)

      Remove the reverse clutch balancer and reverse clutch return spring sub-assembly (rear) from the overdrive direct clutch drum sub-assembly.

    4. B001VQGE01
      Text in Illustration
      *1 No. 4 Clutch Piston
      *a Oil Hole

      While holding the overdrive direct clutch drum sub-assembly, apply compressed air to the oil hole to remove the No. 4 clutch piston.

    5. Remove the O-ring from the No. 4 clutch piston.

  33. INSPECT REVERSE CLUTCH RETURN SPRING SUB-ASSEMBLY (REAR)

    Click here

  34. REMOVE OVERDRIVE DIRECT CLUTCH DRUM SUB-ASSEMBLY


    1. B001Z5GE01
      Text in Illustration
      *1 Snap Ring
      *2 Overdrive Direct Clutch Drum Sub-assembly

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

      Tech Tips

      If the overdrive direct clutch drum sub-assembly is difficult to remove, reinstall the snap ring for the overdrive direct clutch discs.

    2. Remove the 3 O-rings from the overdrive direct clutch drum sub-assembly.

  35. REMOVE REVERSE CLUTCH PISTON SUB-ASSEMBLY


    1. B001X0NE01

      Place SST on the No. 3 clutch balancer, and compress the reverse clutch return spring sub-assembly (front) with a press.

      SST
      09380-50010   ( 09381-05020 )

    2. Using SST, remove the snap ring.

      SST
      09350-30020   ( 09350-07070 )
    3. B001XSAE01
      Text in Illustration
      *1 No. 3 Clutch Balancer
      *2 Reverse Clutch Return Spring Sub-assembly (Front)

      Remove the No. 3 clutch balancer and reverse clutch return spring sub-assembly (front).

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

    5. B001VSBE01
      Text in Illustration
      *1 Reverse Clutch Piston Sub-assembly
      *a Oil Hole

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

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

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

  36. INSPECT REVERSE CLUTCH RETURN SPRING SUB-ASSEMBLY (FRONT)

    Click here

  37. INSPECT REVERSE CLUTCH DRUM SUB-ASSEMBLY

    Click here

  38. REMOVE FORWARD MULTIPLE DISC CLUTCH ASSEMBLY WITH FRONT PLANETARY RING GEAR


    1. B001Z0WE01
      Text in Illustration
      *1 Forward Multiple Disc Clutch Assembly with Front Planetary Ring Gear
      *2 Thrust Needle Roller Bearing
      *3 Thrust Bearing Race

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

  39. REMOVE FRONT PLANETARY RING GEAR


    1. B001ZXQE01
      Text in Illustration
      *1 Front Planetary Ring Gear
      *2 Snap Ring
      *3 Forward Multiple Disc Clutch Assembly

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

  40. REMOVE FORWARD MULTIPLE CLUTCH DISC SET


    1. B001ZCTE01
      Text in Illustration
      *a Protective Tape

      Using a screwdriver, remove the snap ring.

      Note

      Be careful not to damage the forward multiple clutch disc assembly.

      Tech Tips

      Tape the screwdriver tip before use.

    2. B002018E01
      Text in Illustration
      *1 Forward Clutch Flange
      *2 Forward Multiple Clutch Disc
      *3 Forward Multiple Clutch Plate

      Remove the forward clutch flange, 7 forward multiple clutch discs and 7 forward multiple clutch plates.

  41. INSPECT FORWARD MULTIPLE CLUTCH DISC

    Click here

  42. REMOVE FORWARD CLUTCH PISTON


    1. B001X6JE01

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

      SST
      09380-50010   ( 09381-05020 )

    2. Using SST, remove the snap ring.

      SST
      09350-30020   ( 09350-07070 )
    3. B001YPNE01
      Text in Illustration
      *1 No. 1 Clutch Balancer
      *2 Forward Clutch Return Spring Sub-assembly

      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. B001XFNE05
      Text in Illustration
      *a Oil Hole

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

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

  43. INSPECT FORWARD CLUTCH RETURN SPRING SUB-ASSEMBLY

    Click here

  44. INSPECT FORWARD CLUTCH DRUM SUB-ASSEMBLY

    Click here

  45. REMOVE FORWARD MULTIPLE DISC CLUTCH HUB


    1. B001YBBE01
      Text in Illustration
      *1 Forward Multiple Disc Clutch Hub
      *2 Thrust Bearing Race
      *3 Thrust Needle Roller Bearing

      Remove the forward multiple disc clutch hub from the automatic transmission case sub-assembly.

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

  46. REMOVE SUN GEAR INPUT DRUM SUB-ASSEMBLY


    1. B001X9EE01
      Text in Illustration
      *1 Sun Gear Input Drum Sub-assembly
      *2 Thrust Needle Roller Bearing
      *3 Thrust Bearing Race

      Remove the sun gear input drum sub-assembly, thrust needle roller bearing and thrust bearing race from the automatic transmission case sub-assembly.

  47. INSPECT SUN GEAR INPUT DRUM SUB-ASSEMBLY

    Click here

  48. REMOVE REAR PLANETARY SUN GEAR SUB-ASSEMBLY


    1. B001ZL6E01
      Text in Illustration
      *1 Rear Planetary Sun Gear Sub-assembly
      *2 Thrust Bearing Race

      Remove the rear planetary sun gear sub-assembly and thrust bearing race from the automatic transmission case sub-assembly.

  49. INSPECT REAR PLANETARY SUN GEAR SUB-ASSEMBLY

    Click here

  50. REMOVE ONE-WAY CLUTCH OUTER RACE WITH NO. 1 ONE-WAY CLUTCH


    1. B001XYSE05

      Using SST, remove the snap ring from the automatic transmission case sub-assembly.

      SST
      09350-30020   ( 09350-07060 )
    2. B001YMVE01
      Text in Illustration
      *1 Thrust Needle Roller Bearing
      *2 One-way Clutch Outer Race with No. 1 One-way Clutch
      *3 Rear Planetary Gear Assembly
      *4 Thrust Bearing Race

      Remove the thrust needle roller bearing, rear planetary gear assembly, one-way clutch outer race with No. 1 one-way clutch and thrust bearing race from the automatic transmission case sub-assembly.

    3. B001ZFEE03
      Text in Illustration
      *1 One-way Clutch Outer Race with No. 1 One-way Clutch
      *2 Rear Planetary Gear Assembly

      Remove the one-way clutch outer race with No. 1 one-way clutch from the rear planetary gear assembly.

  51. INSPECT NO. 1 ONE-WAY CLUTCH

    Click here

  52. REMOVE NO. 1 ONE-WAY CLUTCH


    1. B001ZQ3E01
      Text in Illustration
      *1 Snap Ring
      *2 No. 1 One-way Clutch
      *3 One-way Clutch Outer Race

      Remove the snap ring and No. 1 one-way clutch from the one-way clutch outer race.

  53. INSPECT REAR PLANETARY GEAR ASSEMBLY

    Click here

  54. REMOVE NO. 2 BRAKE DISC SET


    1. Remove the snap ring from the automatic transmission case sub-assembly.

    2. B001XFZE01
      Text in Illustration
      *1 Brake Plate
      *2 No. 2 Brake Disc
      *3 No. 2 Brake Plate
      *4 No. 2 Brake Flange

      Remove the brake plate, 6 No. 2 brake discs, 5 No. 2 brake plates and No. 2 brake flange from the automatic transmission case sub-assembly.

  55. INSPECT NO. 2 BRAKE DISC

    Click here

  56. REMOVE DIRECT MULTIPLE DISC CLUTCH ASSEMBLY WITH REAR PLANETARY RING GEAR AND OUTPUT SHAFT SUB-ASSEMBLY


    1. B001YXLE01
      Text in Illustration
      *1 Thrust Needle Roller Bearing
      *2 Thrust Bearing Race
      *3 Direct Multiple Disc Clutch Assembly with Rear Planetary Ring Gear and Output Shaft Sub-assembly

      Remove the 2 thrust needle roller bearings, 2 thrust bearing races and direct multiple disc clutch assembly with rear planetary ring gear and output shaft sub-assembly from the automatic transmission case sub-assembly.

  57. REMOVE REAR PLANETARY RING GEAR


    1. B001VRAE01
      Text in Illustration
      *1 Rear Planetary Ring Gear
      *2 Snap Ring

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

  58. REMOVE DIRECT MULTIPLE DISC CLUTCH ASSEMBLY


    1. B001X7BE01
      Text in Illustration
      *1 Direct Multiple Disc Clutch Assembly
      *2 Thrust Needle Roller Bearing
      *3 Thrust Bearing Race
      *4 Output Shaft Sub-assembly

      Remove the direct multiple disc clutch assembly from the output shaft sub-assembly.

    2. Remove the thrust needle roller bearing and 2 thrust bearing races from the output shaft sub-assembly.

    3. B002019E01
      Text in Illustration
      *1 Oil Seal Ring

      Remove the 2 oil seal ring from the output shaft sub-assembly.

    4. B001Z4DE02
      Text in Illustration
      *1 Oil Seal Ring

      Remove the oil seal ring from the direct multiple disc clutch assembly.

  59. REMOVE NO. 2 CLUTCH DISC SET


    1. B001Y6HE01
      Text in Illustration
      *a Protective Tape

      Using a screwdriver, remove the snap ring from the direct clutch drum sub-assembly.

      Note

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

      Tech Tips

      Tape the screwdriver tip before use.

    2. B001YKWE01
      Text in Illustration
      *1 No. 2 Clutch Flange
      *2 No. 2 Clutch Disc
      *3 No. 2 Clutch Plate

      Remove the No. 2 clutch flange, 7 No. 2 clutch discs and 7 No. 2 clutch plates from the direct clutch drum sub-assembly.

  60. INSPECT NO. 2 CLUTCH DISC

    Click here

  61. REMOVE DIRECT CLUTCH PISTON


    1. B001YDGE01

      Place SST on the No. 2 clutch balancer, and compress the direct clutch return spring sub-assembly with a press.

      SST
      09387-00020

    2. Using SST, remove the snap ring.

      SST
      09350-30020   ( 09350-07070 )
    3. B001VKPE01
      Text in Illustration
      *1 No. 2 Clutch Balancer
      *2 Direct Clutch Return Spring Sub-assembly

      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. B001XUQE01
      Text in Illustration
      *1 Direct Clutch Piston
      *a Oil Hole

      Hold the direct clutch drum sub-assembly and apply compressed air to the oil hole of the direct clutch drum sub-assembly 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.

  62. INSPECT DIRECT CLUTCH RETURN SPRING SUB-ASSEMBLY

    Click here

  63. REMOVE NO. 2 BRAKE PISTON


    1. B001Y2LE05
      Text in Illustration
      *1 No. 2 Brake Piston Return Spring Sub-assembly
      *2 Snap Ring

      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   ( 09381-05010, 09381-05020, 09381-05030, 09381-05040, 09381-05050 )

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

      SST
      09350-30020   ( 09350-07070 )
    3. B001XYEE04
      Text in Illustration
      *a Oil Hole

      Apply compressed air to the oil hole of the automatic transmission case sub-assembly to remove the No. 2 brake piston from the automatic transmission case sub-assembly.

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

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

    Click here

  65. REMOVE 1ST AND REVERSE BRAKE PLATE STOPPER SPRING


    1. B001Y8U

      Remove the 1st and reverse brake plate stopper spring from the automatic transmission case sub-assembly.

  66. REMOVE OUTPUT SHAFT REAR RADIAL BALL BEARING


    1. Using snap ring pliers, remove the snap ring from the automatic transmission case sub-assembly.

    2. B001X2PE04

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

      SST
      09308-00010