PROCEDURE
REMOVE TRANSMISSION CONTROL SHAFT LEVER LH
Remove the nut, spring washer and transmission control shaft lever LH.
REMOVE PARK/NEUTRAL POSITION SWITCH ASSEMBLY
Using a screwdriver, bend the tabs of the lock washer.
Remove the nut, lock washer and bolt.
Remove 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.
REMOVE OIL COOLER TUBE UNION
Remove the 2 oil cooler tube unions.
Remove the 2 O-rings from the 2 oil cooler tube unions.
REMOVE TRANSMISSION REVOLUTION SENSOR (NT)
REMOVE TRANSMISSION REVOLUTION SENSOR (SP2)
REMOVE AUTOMATIC TRANSMISSION BREATHER TUBE
Remove the 2 bolts and remove the automatic transmission breather tube.
| *1 | No. 1 Breather Plug |
| *2 | Automatic Transmission Breather Hose |
| *3 | Automatic Transmission Breather Tube |
| *4 | O-ring |
Remove the O-ring from the automatic transmission breather tube.
Remove the No. 1 breather plug and automatic transmission breather hose from the automatic transmission breather tube.
REMOVE AUTOMATIC TRANSMISSION HOUSING
Remove the 10 bolts.
Remove the automatic transmission housing.
REMOVE TRANSFER ADAPTER SUB-ASSEMBLY
Remove the 8 bolts.
Remove the rear transfer adapter sub-assembly.
Tech Tips
Use a brass bar and a hammer to remove the rear transfer adapter sub-assembly.
Remove the 2 transfer case ring pins from the rear transfer adapter sub-assembly.
REMOVE TRANSFER ADAPTER OIL SEAL
| *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 sub-assembly.
Tech Tips
Tape the screwdriver with tip before use.
REMOVE REAR TRANSFER CASE ADAPTER OIL RECEIVER
Using snap ring pliers, remove the snap ring and rear transfer case adapter oil receiver.
FIX AUTOMATIC TRANSMISSION CASE SUB-ASSEMBLY
Install the automatic transmission case sub-assembly to an overhaul attachment.
REMOVE AUTOMATIC TRANSMISSION OIL PAN SUB-ASSEMBLY
Note
Do not turn the transmission over as this will contaminate the valve body with foreign matter on the bottom of the automatic transmission oil pan sub-assembly.
Remove the overflow plug and gasket.
Remove the drain plug and gasket.
Remove the 20 bolts, automatic transmission oil pan sub-assembly and gasket.
Examine particles in the pan.
Remove the 4 magnets from the automatic transmission oil pan sub-assembly. Use the removed magnets to collect any steel chips. Look carefully for the chips and particles in the automatic transmission oil pan sub-assembly and on the magnets to anticipate the type of wear which might be found in the transmission.
Result:
| Steel (magnetic) |
|---|
| Bearing, gear and plate wear |
| Brass (non-magnetic) |
|---|
| Bushing wear |
REMOVE VALVE BODY OIL STRAINER ASSEMBLY
Turn over the automatic transmission case sub-assembly.
Remove the valve body oil strainer assembly.
REMOVE TRANSMISSION WIRE
REMOVE TRANSMISSION VALVE BODY ASSEMBLY
REMOVE TRANSMISSION CASE GASKET
Remove the 3 transmission case gaskets.
REMOVE BRAKE DRUM GASKET
Remove the 3 brake drum gaskets.
REMOVE CHECK BALL BODY
| *1 | Check Ball Body |
| *2 | Spring |
Remove the check ball body and spring.
REMOVE C-2 ACCUMULATOR PISTON
Apply compressed air to the oil hole to remove the C-2 accumulator piston and spring.
Remove the 2 O-rings from the C-2 accumulator piston.
Note
Be careful as the C-3 and B-3 accumulator pistons may jump out.
REMOVE B-3 ACCUMULATOR PISTON
Apply compressed air to the oil hole to remove the B-3 accumulator piston and spring.
Remove the 2 O-rings from the B-3 accumulator piston.
Note
Be careful as the C-3 accumulator piston may jump out.
REMOVE C-3 ACCUMULATOR PISTON
Apply compressed air to the oil hole to remove the C-3 accumulator piston and 2 springs.
Remove the 2 O-rings from the C-3 accumulator piston.
REMOVE C-1 ACCUMULATOR VALVE
Remove the C-1 accumulator valve and 2 springs.
REMOVE PARKING LOCK PAWL BRACKET
Remove the 3 bolts and parking lock pawl bracket.
REMOVE PARKING LOCK ROD SUB-ASSEMBLY
Disconnect the parking lock rod sub-assembly from the manual valve lever sub-assembly.
REMOVE PARKING LOCK PAWL SHAFT
| *1 | Parking Lock Pawl |
| *2 | E-ring |
| *3 | Parking Lock Pawl Shaft |
| *4 | Spring |
Pull out the parking lock pawl shaft from the front side, and then remove the parking lock pawl and spring.
Remove the E-ring from the parking lock pawl shaft.
REMOVE MANUAL VALVE LEVER SUB-ASSEMBLY
| *a | Protective Tape |
Using a hammer and a 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
Tape the screwdriver tip before use
Using a pin punch and a hammer, drive out the spring pin.
Tech Tips
Slowly drive out the spring pin so that it does not fall into the transmission case sub-assembly.
Pull the manual valve lever shaft out through the automatic transmission case sub-assembly and remove the manual valve lever sub-assembly.
REMOVE MANUAL VALVE LEVER SHAFT OIL SEAL
| *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.
REMOVE OIL PUMP ASSEMBLY
Remove the 10 bolts.
Using SST, remove the oil pump assembly.
| *1 | No. 1 Thrust Bearing Race |
| *2 | O-ring |
| *3 | Oil Pump Assembly |
Remove the No. 1 thrust bearing race from the oil pump assembly.
Remove the O-ring from the oil pump assembly.
REMOVE CLUTCH DRUM AND INPUT SHAFT ASSEMBLY
Remove the clutch drum and input shaft assembly from the automatic transmission case sub-assembly.
| *1 | Thrust Needle Roller Bearing |
| *2 | No. 2 Thrust Bearing Race |
| *3 | Clutch Drum Thrust Washer |
Remove the clutch drum thrust washer, 2 thrust needle roller bearings and No. 2 thrust bearing race.
INSPECT NO. 2 ONE-WAY CLUTCH ASSEMBLY
REMOVE NO. 2 ONE-WAY CLUTCH ASSEMBLY
| *1 | No. 2 One-way Clutch Assembly |
| *2 | No. 2 Clutch Drum Thrust Washer |
| *3 | Clutch Drum and Input Shaft Assembly |
Remove the No. 2 one-way clutch assembly and No. 2 clutch drum thrust washer from the clutch drum and input shaft assembly.
FIX CLUTCH DRUM AND INPUT SHAFT ASSEMBLY
| *1 | Torque Converter Assembly |
| *2 | Oil Pump Assembly |
| *3 | Clutch Drum and Input shaft assembly |
Place the oil pump assembly onto the torque converter assembly, and then place the clutch drum and input shaft assembly onto the oil pump assembly.
REMOVE REVERSE CLUTCH HUB SUB-ASSEMBLY
| *a | Protective Tape |
Using a screwdriver, remove the snap ring from the clutch drum and input shaft assembly.
Note
Be careful not to damage the reverse clutch piston sub-assembly, clutch drum and input shaft assembly.
Tech Tips
Tape the screwdriver tip before use.
Remove the reverse clutch hub sub-assembly with the reverse clutch reaction sleeve, clutch cushion plate, reverse clutch flange, 5 reverse clutch discs and 4 reverse clutch plates from the reverse clutch hub sub-assembly.
REMOVE REVERSE CLUTCH REACTION SLEEVE
Remove the reverse clutch reaction sleeve from the reverse clutch hub sub-assembly.
REMOVE REVERSE CLUTCH DISC
Remove the clutch cushion plate, reverse clutch flange, 5 reverse clutch discs and 4 clutch plates from the reverse clutch hub sub-assembly.
INSPECT REVERSE CLUTCH DISC
INSPECT REVERSE CLUTCH HUB SUB-ASSEMBLY
REMOVE FORWARD CLUTCH HUB SUB-ASSEMBLY
Remove the forward clutch hub sub-assembly from the clutch drum.
Remove the 2 thrust needle roller bearings from the forward clutch hub sub-assembly.
INSPECT FORWARD CLUTCH HUB SUB-ASSEMBLY
REMOVE MULTIPLE DISC CLUTCH HUB
Remove the multiple disc clutch hub from the clutch drum.
| *1 | No. 3 Thrust Bearing Race |
| *2 | No. 4 Thrust Bearing Race |
Remove the No. 3 thrust bearing race and No. 4 thrust bearing race from the multiple disc clutch hub.
REMOVE INPUT SHAFT ASSEMBLY
Remove the thrust needle roller bearing from the clutch drum.
Remove the input shaft assembly from the clutch drum.
REMOVE INPUT SHAFT OIL SEAL RING
Remove the 3 input shaft oil seal rings from the input shaft assembly.
REMOVE FORWARD MULTIPLE DISC CLUTCH DISC
| *a | Protective Tape |
Using a screwdriver, remove the snap ring.
Note
Be careful not to damage the input shaft assembly.
Tech Tips
Tape the screwdriver tip before use.
Remove the 2 forward clutch flanges, 7 forward multiple disc clutch discs and 6 clutch plates from the input shaft assembly.
INSPECT FORWARD MULTIPLE DISC CLUTCH DISC
REMOVE NO. 1 CLUTCH BALANCER
Place SST on the No. 1 clutch balancer, and compress the forward clutch return spring sub-assembly with a press.
Using SST, remove the snap ring.
| *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 input shaft assembly.
Remove the O-ring from the No. 1 clutch balancer.
INSPECT FORWARD CLUTCH RETURN SPRING SUB-ASSEMBLY
REMOVE FORWARD CLUTCH PISTON
Hold the input shaft assembly by hand and apply compressed air to the input shaft assembly to remove the forward clutch piston.
Remove the 2 O-rings from the forward clutch piston.
REMOVE REVERSE CLUTCH FLANGE
Remove the reverse clutch flange from the clutch drum.
REMOVE DIRECT CLUTCH DISC
| *a | Protective Tape |
Using a screwdriver, remove the 2 snap rings from the clutch drum.
Note
Be careful not to damage the reverse clutch drum.
Tech Tips
Tape the screwdriver tip before use.
Remove the direct clutch flange, 6 direct clutch discs and 6 clutch plates from the clutch drum.
INSPECT DIRECT CLUTCH DISC
REMOVE NO. 3 CLUTCH BALANCER
Place SST on the No. 3 clutch balancer, and compress the reverse clutch return spring sub-assembly with a press.
Using SST, remove the snap ring.
Remove the No. 3 clutch balancer.
REMOVE REVERSE CLUTCH RETURN SPRING SUB-ASSEMBLY
| *1 | Reverse Clutch Return Spring Sub-assembly |
| *2 | O-ring |
| *3 | Reverse Clutch Piston Sub-assembly |
Remove the reverse clutch return spring sub-assembly and O-ring from the reverse clutch piston sub-assembly.
INSPECT REVERSE CLUTCH RETURN SPRING SUB-ASSEMBLY
REMOVE REVERSE CLUTCH PISTON SUB-ASSEMBLY
| *1 | Reverse Clutch Piston Sub-assembly |
| *2 | Clutch Drum |
Remove the reverse clutch piston sub-assembly from the reverse clutch drum.
Remove the O-ring from the reverse clutch piston sub-assembly.
Remove the O-ring from the clutch drum.
REMOVE DIRECT CLUTCH PISTON SUB-ASSEMBLY
Place SST on the No. 2 clutch balancer, and compress the direct clutch return spring sub-assembly with a press.
Using SST, remove the snap ring.
| *a | Protective Tape |
Using 2 screwdrivers, remove the direct clutch piston sub-assembly from the clutch drum.
Note
Be careful not to damage the direct clutch piston sub-assembly.
Tech Tips
Tape the screwdriver tip before use.
Remove the O-ring from the clutch drum.
| *1 | Direct Clutch Piston Sub-assembly |
| *2 | Direct Clutch Return Spring Sub-assembly |
| *3 | No. 2 Clutch Balancer |
Remove the No. 2 clutch balancer and direct clutch return spring sub-assembly from the direct clutch piston sub-assembly.
Remove the 2 O-rings from the direct clutch piston sub-assembly.
INSPECT DIRECT CLUTCH RETURN SPRING SUB-ASSEMBLY
REMOVE NO. 3 BRAKE DISC
| *a | Protective Tape |
Using a screwdriver, remove the snap ring from the automatic transmission case sub-assembly.
Note
Be careful not to damage the automatic transmission case sub-assembly.
Tech Tips
Tape the screwdriver tip before use.
Remove the No. 3 brake flange, brake cushion plate, 4 No. 3 brake discs and 4 No. 3 brake plates from the automatic transmission case sub-assembly.
INSPECT NO. 3 BRAKE DISC
REMOVE ONE-WAY CLUTCH ASSEMBLY
Remove the one-way clutch assembly and No. 1 planetary carrier thrust washer from the automatic transmission case sub-assembly.
REMOVE 2ND BRAKE CYLINDER
Using SST, remove the snap ring.
Remove the 2nd brake cylinder from the automatic transmission case sub-assembly.
REMOVE 2ND BRAKE PISTON
| *a | Protective Tape |
Using SST, a screwdriver and a press, compress the 2nd brake piston return spring sub-assembly and remove the snap ring.
Note
Be careful not to damage the 2nd brake cylinder.
Tech Tips
Tape the screwdriver tip before use.
Remove the 2nd brake piston return spring sub-assembly.
Hold the 2nd brake cylinder and apply compressed air to the 2nd brake cylinder to remove the 2nd brake piston.
| *1 | O-ring |
Remove the 2 O-rings from the 2nd brake piston.
INSPECT NO. 3 BRAKE PISTON RETURN SPRING SUB-ASSEMBLY
REMOVE FRONT PLANETARY GEAR ASSEMBLY
| *1 | One-way Clutch Inner Race |
| *2 | Front Planetary Gear Assembly |
Remove the front planetary gear assembly and one-way clutch inner race from the automatic transmission case sub-assembly.
| *1 | No. 2 Planetary Carrier Thrust Washer |
| *2 | Thrust Needle Roller Bearing |
| *3 | No. 3 Thrust Bearing Race |
Remove the thrust needle roller bearing, No. 3 thrust bearing race and No. 2 planetary carrier thrust washer from the automatic transmission case sub-assembly.
INSPECT FRONT PLANETARY GEAR ASSEMBLY
INSPECT ONE-WAY CLUTCH ASSEMBLY
REMOVE FRONT PLANETARY RING GEAR
Remove the front planetary ring gear and thrust needle roller bearing from the automatic transmission case sub-assembly.
REMOVE CENTER PLANETARY RING GEAR
| *a | Protective Tape |
Using a screwdriver, remove the snap ring.
Note
Be careful not to damage the front planetary ring gear and center planetary ring gear.
Tech Tips
Tape the screwdriver tip before use.
| *1 | Center Planetary Ring Gear |
| *2 | Front Planetary Ring Gear Flange |
| *3 | Front Planetary Ring Gear |
Remove the center planetary ring gear and front planetary ring gear flange from the front planetary ring gear.
REMOVE NO. 1 BRAKE DISC
Remove the No. 1 brake flange, 3 No. 1 brake discs and 3 No. 1 brake plates from the automatic transmission case sub-assembly.
INSPECT NO. 1 BRAKE DISC
REMOVE NO. 1 BRAKE CYLINDER
| *a | Protective Tape |
Using a screwdriver, remove the snap ring from the automatic transmission case sub-assembly.
Note
Be careful not to damage the automatic transmission case sub-assembly.
Tech Tips
Tape the screwdriver tip before use.
| *1 | Brake Piston Return Spring Sub-assembly |
| *2 | No. 1 Brake Cylinder |
Remove the brake piston return spring sub-assembly, No. 1 brake piston and No. 1 brake cylinder from the automatic transmission case sub-assembly.
INSPECT BRAKE PISTON RETURN SPRING SUB-ASSEMBLY
REMOVE NO. 1 BRAKE PISTON
Hold the No. 1 brake cylinder and apply compressed air to the No. 1 brake cylinder to remove the No. 1 brake piston.
Tech Tips
If the piston does not pop out with compressed air, lift the piston out with needle-nose pliers.
Remove the 2 O-rings from the No. 1 brake piston.
REMOVE NO. 2 BRAKE DISC
| *a | Protective Tape |
Using a screwdriver, remove the snap ring from the automatic transmission case sub-assembly.
Note
Be careful not to damage the automatic transmission case sub-assembly.
Tech Tips
Tape the screwdriver tip before use.
Remove the No. 2 brake flange, 3 No. 2 brake discs, 3 No. 2 brake plates and No. 2 brake piston return spring from the automatic transmission case sub-assembly.
INSPECT NO. 2 BRAKE DISC
INSPECT NO. 2 BRAKE PISTON RETURN SPRING SUB-ASSEMBLY
REMOVE NO. 2 BRAKE PISTON
Apply compressed air to the transmission case to remove the No. 2 brake piston.
Tech Tips
If the No. 2 brake piston does not pop out with compressed air, lift the No. 2 brake piston out with needle-nose pliers.
Remove the 2 O-rings from the No. 2 brake piston.
Remove the No. 2 brake cylinder from the automatic transmission case sub-assembly.
REMOVE CENTER PLANETARY GEAR ASSEMBLY
| *1 | No. 4 Thrust Bearing Race |
| *2 | Center Planetary Gear Assembly |
| *3 | Planetary Sun Gear |
Remove the No. 4 thrust bearing race, center planetary gear and planetary sun gear from the automatic transmission case sub-assembly.
INSPECT CENTER PLANETARY GEAR ASSEMBLY
REMOVE INTERMEDIATE SHAFT
| *a | Protective Tape |
Using a screwdriver, remove the snap ring from the automatic transmission case sub-assembly.
Note
Be careful not to damage the automatic transmission case sub-assembly.
Tech Tips
Tape the screwdriver tip before use.
Remove the intermediate shaft with the No. 3 one-way clutch assembly from the automatic transmission case sub-assembly.
INSPECT NO. 3 ONE-WAY CLUTCH ASSEMBLY
REMOVE NO. 3 ONE-WAY CLUTCH ASSEMBLY
| *1 | No. 3 One-way Clutch Assembly |
| *2 | One-way Clutch Inner Race |
Remove the No. 3 one-way clutch assembly and one-way clutch inner race from the intermediate shaft.
REMOVE REAR PLANETARY RING GEAR FLANGE SUB-ASSEMBLY WITH REAR PLANETARY RING GEAR
| *1 | No. 7 Thrust Bearing Race |
| *2 | Thrust Needle Roller Bearing |
| *3 | No. 8 Thrust Bearing Race |
| *4 | Rear Planetary Ring Gear Flange Sub-assembly |
Remove the rear planetary ring gear flange sub-assembly with rear planetary ring gear, No. 7 thrust bearing race, thrust needle roller bearing and No. 8 thrust bearing race from the intermediate shaft.
INSPECT REAR PLANETARY RING GEAR FLANGE SUB-ASSEMBLY
REMOVE REAR PLANETARY RING GEAR
| *a | Protective Tape |
Using a screwdriver, remove the snap ring from the rear planetary ring gear flange sub-assembly with rear planetary ring gear.
Note
Be careful not to damage the rear planetary ring gear flange sub-assembly with rear planetary ring gear.
Tech Tips
Tape the screwdriver tip before use.
| *1 | Rear Planetary Ring Gear Flange Sub-assembly |
| *2 | Rear Planetary Ring Gear |
Remove the rear planetary ring gear from the rear planetary ring gear flange sub-assembly.
INSPECT INTERMEDIATE SHAFT
REMOVE BRAKE PLATE STOPPER SPRING
Remove the brake plate stopper spring from the automatic transmission case sub-assembly.
REMOVE NO. 4 BRAKE DISC
Remove the 7 No. 4 brake plates, 8 No. 4 brake discs and 2 No. 4 brake flanges from the automatic transmission case sub-assembly.
INSPECT NO. 4 BRAKE DISC
REMOVE REAR PLANETARY GEAR ASSEMBLY
Remove the rear planetary gear assembly from the automatic transmission case sub-assembly.
Remove the 2 thrust needle roller bearings from the rear planetary gear assembly.
Remove the No. 9 thrust bearing race from the automatic transmission case sub-assembly.
INSPECT REAR PLANETARY GEAR ASSEMBLY
REMOVE 1ST AND REVERSE BRAKE RETURN SPRING SUB-ASSEMBLY
| *1 | Snap Ring |
Place SST on the 1st and reverse brake return spring sub-assembly and compress the 1st and reverse brake return spring sub-assembly.
Using SST, remove the snap ring and 1st and reverse brake return spring sub-assembly.
INSPECT 1ST AND REVERSE BRAKE RETURN SPRING SUB-ASSEMBLY
REMOVE 1ST AND REVERSE BRAKE PISTON
Apply compressed air to the automatic transmission case sub-assembly to remove the 1st and reverse brake piston.
Tech Tips
If the 1st and reverse brake piston does not pop out with compressed air, lift the 1st and reverse brake piston out with needle-nose pliers.
Remove the O-ring from the 1st and reverse brake piston.
REMOVE BRAKE REACTION SLEEVE
Using SST, remove the brake reaction sleeve.
Remove the 2 O-rings from the brake reaction sleeve.
REMOVE NO. 4 BRAKE PISTON
Using SST, remove the No. 4 brake piston.
Remove the 2 O-rings from the No. 4 brake piston.