AUTOMATIC TRANSMISSION UNIT(for 2GR) DISASSEMBLY

PROCEDURE


  1. FIX AUTOMATIC TRANSMISSION ASSEMBLY


    1. B003TAW

      Install the automatic transmission assembly to an overhaul attachment.

  2. REMOVE WIRE HARNESS CLAMP BRACKET


    1. B003U7H

      Remove the 2 bolts and the 2 wire harness clamp brackets from the automatic transmission case sub-assembly.

    2. B003WQ2

      Remove the bolt and the wire harness clamp bracket from the automatic transmission case sub-assembly.

  3. REMOVE TRANSMISSION CONTROL SHAFT LEVER RH

    B003UUV

    1. Remove the nut, spring washer and the transmission control shaft lever RH from the manual valve lever shaft.

  4. REMOVE PARK/NEUTRAL POSITION SWITCH ASSEMBLY


    1. B003T1O

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

    2. Remove the nut and the lock washer from the park/neutral position switch assembly.

    3. Remove the bolt and the park/neutral position switch assembly from the automatic transmission case sub-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.

  5. REMOVE TRANSMISSION OIL COOLER


    1. B003WLL

      Remove the 3 bolts and the transmission oil cooler from the automatic transmission case sub-assembly.

    2. B003TQ3C02
      *1 O-ring

      Remove the 2 O-rings from the transmission oil cooler.

  6. REMOVE BREATHER PLUG HOSE


    1. B003VJH

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

    2. Remove the O-ring from the breather plug hose.

  7. REMOVE AUTOMATIC TRANSMISSION FLANGE YOKE ASSEMBLY


    1. B003V33N02

      Using SST and a hammer, loosen the staked part of the lock nut.

      SST
      09930-00010

      Note


      • Be sure to use SST with the tapered surface facing the shaft.

      • Do not grind the tip of SST with a grinder or other device.

      • Completely loosen the staked part of the lock nut when removing it

      • Do not damage the threads of the shaft.

    2. B003SVUC01
      *a Hold
      *b Turn

      Using SST and a 30 mm deep socket wrench, remove the lock nut.

      SST
      09330-00021
      09950-30012   ( 09955-03040 )

    3. Remove SST.

    4. Tap the automatic transmission flange yoke assembly with a plastic-faced hammer to remove it.

    5. Remove the 2 rear No. 1 output shaft bearing spacers and rear cover sleeve.

    6. B003WGA

      Using a screwdriver, pry out the oil seal from the automatic transmission flange yoke assembly.

      Note

      Do not damage the automatic transmission flange yoke assembly.

  8. REMOVE AUTOMATIC TRANSMISSION OIL PAN SUB-ASSEMBLY

    Note

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


    1. Remove the overflow plug and gasket.

    2. Remove the drain plug and gasket.

    3. B003WNI

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

      Note

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

    4. B003TJW

      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.

        Result
        Steel (magnetic)
        Bearing, gear and clutch plate wear
        Brass (non-magnetic)
        Bushing wear

  9. REMOVE VALVE BODY OIL STRAINER ASSEMBLY


    1. Turn over the automatic transmission case sub-assembly.

    2. B003TSS

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

    3. B003VS2

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

  10. REMOVE TRANSMISSION VALVE BODY ASSEMBLY

    B003VJFC02
    *1 Lock Plate
    *2 ATF Temperature Sensor

    1. Remove the bolt, lock plate and ATF temperature sensor.

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

    3. Disconnect the oil pressure switch connector.

    4. Disconnect the 9 shift solenoid valve connectors.

    5. B003UK3C02
      *1 Detent Spring Cover
      *2 Detent Spring

      Remove the bolt, detent spring cover and detent spring.

    6. B003VMV

      Remove the 17 bolts and transmission valve body assembly.

    7. B003UMZC02
      *1 Manual Valve Connecting Rod
      *2 Manual Valve Lever Sub-assembly

      Disconnect the manual valve connecting rod from the manual valve lever sub-assembly

  11. REMOVE CHECK BALL BODY


    1. B003VQSC02
      *1 Check Ball Body
      *2 Spring

      Remove the check ball body and spring.

  12. REMOVE TRANSMISSION WIRE


    1. B003SZ7

      Disconnect the 3 connectors from the 3 transmission revolution sensors.

    2. B003T4P

      Remove the bolt and pull out the transmission wire.

    3. Remove the O-ring from the transmission wire connector.

    4. B003T2K

      Remove the 2 bolts and the 2 valve body wire harness clamps from the automatic transmission case sub-assembly.

  13. REMOVE TRANSMISSION REVOLUTION SENSOR

    B003X0TC01
    *1 Transmission Revolution Sensor NT
    *2 Transmission Revolution Sensor NC3
    *3 Transmission Revolution Sensor SP2

    1. Remove the 2 bolts and 2 transmission revolution sensors NC3 and SP2.

    2. Using ''TORX'' socket wrench T30, remove the bolt and transmission revolution sensor NT from the oil pump assembly.

    3. Remove the O-ring from the transmission revolution sensor NT.

  14. REMOVE AUTOMATIC TRANSMISSION CASE PLUG


    1. B003UAA

      Remove the automatic transmission case plug and O-ring.

  15. REMOVE PARKING LOCK PAWL BRACKET


    1. B003UCS

      Remove the 3 bolts and parking lock pawl bracket.

  16. REMOVE PARKING LOCK ROD SUB-ASSEMBLY


    1. B003WGZ

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

  17. REMOVE PARKING LOCK PAWL SHAFT

    B003WUKC01
    *1 Parking Lock Pawl
    *2 Parking Lock Pawl Shaft
    *3 Spring
    *4 E-ring
    B003WAF Front Side

    1. 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.

  18. REMOVE MANUAL VALVE LEVER SUB-ASSEMBLY


    1. B003VNQC01
      *1 Protective Tape

      Using a screwdriver and hammer, 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. B003W7K

      Using a pin punch (3 mm) and hammer, tap out 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. Pull the manual valve lever shaft out through the automatic transmission case sub-assembly, and remove the manual valve lever sub-assembly.

  19. REMOVE MANUAL VALVE LEVER SHAFT OIL SEAL


    1. B003UHCC01
      *1 Protective Tape

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

      Note

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

      Tech Tips

      Wrap the tip of the screwdriver with protective tape.

  20. REMOVE OIL PUMP ASSEMBLY

    B003V3I

    1. Remove the 11 bolts.

    2. B003VB2

      Pull out the oil pump assembly.

      Note

      Do not damage the oil pump assembly.

    3. B003W86C01
      *1 Oil Pump Assembly
      *2 Oil Pump O-ring

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

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

    B003U8RC01
    *1 Thrust Needle Roller Bearing
    *2 Thrust Bearing Race

    1. 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.

  22. REMOVE NO. 1 BRAKE DISC


    1. B003V1XC01
      *1 No. 1 Brake Plate
      *2 No. 1 Brake Disc
      *3 No. 1 Brake Flange

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

  23. INSPECT NO. 1 BRAKE DISC

    Click here

  24. REMOVE FRONT PLANETARY GEAR ASSEMBLY


    1. B003UJ6

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

    2. B003T0RC01
      *1 Planetary Sun Gear

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

    3. B003WRWC01
      *1 Front Planetary Gear Shaft Snap Ring

      Remove the 3 front planetary gear shaft snap rings from the front planetary gear assembly.

    4. B003V8ZC01
      *1 Planetary Carrier Thrust Washer

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

    5. B003U9QC01
      *1 Front Planetary Gear Shaft Snap Ring

      Remove the 2 front planetary gear shaft snap rings from the front planetary gear assembly.

    6. B003VKKC01
      *1 Front Planetary Gear Thrust Needle Roller Bearing

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

  25. INSPECT FRONT PLANETARY GEAR ASSEMBLY

    Click here

  26. REMOVE NO. 3 CLUTCH DISC


    1. B003UT2C01
      *1 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

      Wrap the tip of the screwdriver with protective tape.

    2. B003UIHC01
      *1 No. 3 Clutch Flange
      *2 No. 3 Clutch Disc
      *3 No. 3 Clutch Plate

      Remove the No. 3 Clutch flange, 4 No. 3 Clutch discs and 4 No. 3 Clutch plates from the overdrive direct clutch drum sub-assembly.

  27. INSPECT NO. 3 CLUTCH DISC

    Click here

  28. REMOVE REVERSE CLUTCH DISC


    1. B003WMGC01
      *1 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

      Wrap the tip of the screwdriver with protective tape.

    2. B003TI9C01
      *1 Reveres Clutch Flange
      *2 Reveres Clutch Disc
      *3 Reveres Clutch Plate

      Remove the reveres clutch flange, 5 reveres clutch discs and 5 reveres clutch plates from the reveres clutch drum sub-assembly.

  29. INSPECT REVERSE CLUTCH DISC

    Click here

  30. REMOVE REVERSE CLUTCH PISTON

    B003X31N01

    1. Place SST on the reverse clutch balancer, and compress the reveres 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. B003WW1C01
      *1 Reverse Clutch Balancer
      *2 Reveres Clutch Return Spring Sub-assembly

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

    4. B003VCXC01
      *1 Reveres Clutch Piston
      *a Oil Hole

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

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

  31. INSPECT REVERSE CLUTCH RETURN SPRING SUB-ASSEMBLY

    Click here

  32. INSPECT REVERSE CLUTCH DRUM SUB-ASSEMBLY

    B003X8PC01
    *1 Snap Ring
    *2 Reverse Clutch Drum Sub-assembly

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

      Tech Tips

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

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

  33. REMOVE OVERDRIVE DIRECT CLUTCH PISTON SUB-ASSEMBLY

    B003WNAN01

    1. Place SST on the No. 3 clutch balancer, and compress the overdrive 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. B003WV0C02
      *1 No. 3 Clutch Balancer
      *2 Overdrive Clutch Return Spring Sub-assembly

      Remove the No. 3 clutch balancer and overdrive clutch return spring sub-assembly.

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

    5. B003WJSC01
      *1 Overdrive Direct Clutch Piston Sub-assembly
      *a Oil Hole

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

    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.

  34. INSPECT OVERDRIVE CLUTCH RETURN SPRING SUB-ASSEMBLY

    Click here

  35. INSPECT OVERDRIVE DIRECT CLUTCH DRUM SUB-ASSEMBLY

    Click here

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


    1. B003UZ7C01
      *1 Front Planetary Ring Gear
      *2 Forward Multiple Disc Clutch assembly
      *3 Thrust Needle Roller Bearing
      *4 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.

  37. REMOVE FRONT PLANETARY RING GEAR


    1. B003URUC01
      *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.

  38. REMOVE FORWARD MULTIPLE CLUTCH DISC


    1. B003URIC01
      *1 Protective Tape

      Using a screwdriver, remove the snap ring.

      Note

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

      Tech Tips

      Wrap the tip of the screwdriver with protective tape.

    2. B003T3KC01
      *1 Forward Clutch Flange
      *2 Forward Multiple Clutch Disc
      *3 Forward Multiple Clutch Plate
      *4 Clutch Cushion Plate

      Remove the forward clutch flange, 5 forward multiple clutch discs, 5 forward multiple clutch plates and clutch cushion plate.

  39. INSPECT FORWARD MULTIPLE CLUTCH DISC

    Click here

  40. REMOVE FORWARD CLUTCH PISTON


    1. B003TH9N01

      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. B003W15C01
      *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. B003WN1C01
      *a Oil Hole
      *1 Forward Clutch Piston

      Hold the forward clutch piston 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.

  41. INSPECT FORWARD CLUTCH RETURN SPRING SUB-ASSEMBLY

    Click here

  42. INSPECT FORWARD CLUTCH DRUM SUB-ASSEMBLY

    Click here

  43. REMOVE MULTIPLE DISC CLUTCH HUB


    1. B003UZDC01
      *1 Multiple Disc Clutch Hub
      *2 Thrust Bearing Race
      *3 Thrust Needle Roller Bearing

      Remove the 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.

  44. REMOVE SUN GEAR INPUT DRUM SUB-ASSEMBLY


    1. B003UZYC01
      *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.

  45. INSPECT SUN GEAR INPUT DRUM SUB-ASSEMBLY

    Click here

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

    B003SWHN01

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

      SST
      09350-30020   ( 09350-07060 )
    2. B003U23

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

  47. REMOVE REAR PLANETARY SUN GEAR ASSEMBLY


    1. B003VM4C01
      *1 Rear Planetary Sun Gear Assembly
      *2 Thrust Bearing Race

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

  48. INSPECT REAR PLANETARY SUN GEAR ASSEMBLY

    Click here

  49. REMOVE REAR PLANETARY GEAR ASSEMBLY


    1. B003X8LC01
      *1 Thrust Needle Roller Bearing
      *2 Rear Planetary Gear Assembly
      *3 Thrust Bearing Race

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

  50. INSPECT NO. 1 ONE-WAY CLUTCH

    Click here

  51. REMOVE NO. 1 ONE-WAY CLUTCH


    1. B003T1FC01
      *1 Snap Ring
      *2 No.1 One-way Clutch
      *3 One-way Clutch Outer Race

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

  52. INSPECT REAR PLANETARY GEAR ASSEMBLY

    Click here

  53. REMOVE NO. 2 BRAKE DISC


    1. B003TDFC01
      *1 Brake Plate
      *2 No. 2 Brake Disc
      *3 No. 2 Brake Plate
      *4 No. 2 Brake Flange

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

  54. INSPECT NO. 2 BRAKE DISC

    Click here

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


    1. B003WEIC01
      *1 Thrust Needle Roller Bearing
      *2 Thrust Bearing Race

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

  56. REMOVE REAR PLANETARY RING GEAR


    1. B003VMIC01
      *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.

  57. REMOVE MULTIPLE DISC CLUTCH ASSEMBLY


    1. B003UZHC01
      *1 Multiple Disc Clutch Assembly
      *2 Thrust Needle Roller Bearing
      *3 Thrust Bearing Race
      *4 Output Shaft Sub-assembly

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

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

    3. B003T5XC01
      *1 Oil Seal Ring

      Remove the 3 oil seal rings from the output shaft sub-assembly.

    4. B003VJEC01
      *1 Oil Seal Ring

      Remove the 2 oil seal rings from the multiple disc clutch assembly.

  58. REMOVE NO. 2 CLUTCH DISC


    1. B003UL2C01
      *1 No. 2 Clutch Flange
      *2 No. 2 Clutch Disc
      *3 No. 2 Clutch Plate
      *4 Protective Tape

      Remove the snap ring and No. 2 clutch flange, 5 No. 2 clutch discs and 5 No. 2 clutch plates from the direct clutch drum sub-assembly.

      Note

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

      Tech Tips

      Wrap the tip of the screwdriver with protective tape.

  59. INSPECT NO. 2 CLUTCH DISC

    Click here

  60. REMOVE DIRECT CLUTCH PISTON

    B003VBVN02

    1. 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. B003X8RC01
      *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. B003TU4C01
      *a Oil Hole
      *1 Direct Clutch Piston

      Hold the direct clutch piston 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.

  61. INSPECT DIRECT CLUTCH RETURN SPRING SUB-ASSEMBLY

    Click here

  62. REMOVE NO. 2 BRAKE PISTON


    1. B003T68C01
      *1 Snap Ring
      *2 2nd Brake Piston Return Spring Sub-assembly

      Set SST on the 2nd brake piston return spring sub-assembly, tighten SST and compress the 2nd brake piston return spring sub-assembly.

      SST
      09380-50010   ( 09381-05010, 09381-05020 )

    2. Using SST, remove the snap ring and the 2nd brake piston return spring sub-assembly.

    3. B003XACC01
      *a Oil Hole

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

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

  63. INSPECT 2ND BRAKE PISTON RETURN SPRING SUB-ASSEMBLY

    Click here

  64. REMOVE BRAKE PLATE STOPPER SPRING


    1. Remove the 2 brake plate stopper springs.

  65. REMOVE AUTOMATIC TRANSMISSION REAR OIL SEAL


    1. B003UWVC01
      *1 Automatic Transmission Rear Oil Seal

      Using SST, tap out the automatic transmission rear oil seal.

      SST
      09308-00010

  66. REMOVE OUTPUT SHAFT REAR RADIAL BALL BEARING


    1. B003X9PC01
      *1 Output Shaft Rear Radial Ball Bearing

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

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

      SST
      09308-00010