AUTOMATIC TRANSMISSION UNIT DISASSEMBLY


  1. REMOVE DRAIN PLUG SUB-ASSEMBLY

  2. REMOVE BREATHER HOSE

    A00JZFUE01

    1. Remove the breather hose plug with the breather hose.

    2. Remove the breather hose from the breather hose plug.

  3. REMOVE TRANSMISSION CONTROL SHAFT LEVER LH

    A00JXNNE02

    1. Remove the nut, spring washer and control shaft lever.

  4. REMOVE PARK/NEUTRAL POSITION SWITCH ASSEMBLY

    A00JXZM

    1. Using a screwdriver, bend the tab of the lock washer.

    2. Remove the nut and lock washer.

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

  5. REMOVE ATF TEMPERATURE SENSOR

    A00JZT0E01

    1. Remove the sensor.

    2. Remove the O-ring from the sensor.

  6. REMOVE OIL COOLER TUBE UNION

    A00JZV4E01

    1. Remove the 2 tube unions.

    2. Remove the O-ring from each tube union.

  7. REMOVE SPEED SENSOR NC0

    A00K29FE01

    1. Remove the bolt and sensor.

    2. Remove the O-ring from the sensor.

  8. REMOVE SPEED SENSOR SP2

    A00JYTAE01

    1. Remove the bolt and sensor.

    2. Remove the O-ring from the sensor.

  9. REMOVE AUTOMATIC TRANSMISSION HOUSING

    A00K1H9

    1. Remove the 6 bolts.

    2. Remove the transmission housing.

  10. FIX TRANSMISSION CASE

    A00K1TQE01

    1. Install the transmission case to an overhaul attachment.

  11. REMOVE REAR TRANSFER ADAPTER

    A00K0H0

    1. Remove the 8 bolts.

    2. Remove the rear transfer adaptor.

  12. REMOVE TRANSFER CASE ADAPTER REAR OIL SEAL

    A00JYB5

    1. Using a screwdriver, pry out the oil seal.

  13. REMOVE TRANSFER CASE REAR ADAPTER OIL RECEIVER

    A00JW6V

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

    2. Remove the transfer case rear adaptor oil receiver from the rear transfer adaptor.

  14. REMOVE SENSOR ROTOR

    A00JX7F

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

    2. A00JV5V

      Remove the sensor rotor and key.

  15. REMOVE AUTOMATIC TRANSMISSION OIL PAN SUB-ASSEMBLY

    A00JWAQ

    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 19 bolts.

    2. A00JUKVE04

      Insert the blade of an oil pan seal cutter between the transmission case and oil pan, and cut off the applied sealer.

      Note

      Be careful not to damage the oil pan and flange.

    3. Remove the pan from the transmission case.

  16. INSPECT AUTOMATIC TRANSMISSION OIL PAN SUB-ASSEMBLY


    1. Remove the magnets and use them to collect steel particles.

    2. Carefully look at the foreign matter and particles in the pan and on the magnets to anticipate the type of wear you will find in the transmission.


      • Steel (magnetic): bearing, gear and clutch plate wear.

      • Brass (non-magnetic): bush wear.

  17. REMOVE VALVE BODY OIL STRAINER ASSEMBLY


    1. Turn over the transmission.

    2. A00JVLWE02

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

    3. Remove the 3 gaskets from the oil strainer.

  18. REMOVE TRANSMISSION WIRE

    A00JWTE

    1. Remove the bolt and temperature sensor clamp, and disconnect the temperature sensor.

    2. Disconnect the 4 connectors from the shift solenoid valves.

    3. A00K1CCE04

      Remove the bolt and stopper plate from the case.

    4. Pull out the transmission wire from the transmission case to remove it.

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

  19. REMOVE TRANSMISSION VALVE BODY ASSEMBLY

    A00JWYJE01

    1. Remove the 20 bolts and valve body.

  20. REMOVE CHECK BALL BODY

    A00JY4DE02
    Text in Illustration
    *1 Check Ball Body
    *2 Spring

    1. Remove the check ball body and spring.

  21. REMOVE B-2 ACCUMULATOR PISTON

    A00JYRUE01

    1. Apply compressed air to the oil hole to remove the B-2 accumulator piston and spring.

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

  22. REMOVE C-2 ACCUMULATOR PISTON

    A00JYRUE02

    1. Apply compressed air to the oil hole to remove the C-2 accumulator piston and 2 springs.

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

  23. REMOVE B-0 ACCUMULATOR PISTON

    A00JYHGE01

    1. Apply compressed air to the oil hole to remove the B-0 accumulator piston and spring.

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

  24. REMOVE C-0 ACCUMULATOR PISTON

    A00JXPNE01

    1. Apply compressed air to the oil hole to remove the C-0 accumulator piston and 2 springs.

    2. Remove the O-ring from the piston.

  25. REMOVE PARKING LOCK PAWL BRACKET

    A00JZDGE01

    1. Remove the 3 bolts and bracket.

  26. REMOVE PARKING LOCK ROD SUB-ASSEMBLY

    A00JW88E01

    1. Disconnect the parking lock rod from the manual valve lever to remove it.

  27. REMOVE PARKING LOCK PAWL

    A00JXV0E04
    Text in Illustration
    *1 Parking Lock Pawl Shaft
    *2 Lock Pawl
    *3 Spring
    *4 E-Ring

    1. Pull out the parking lock pawl shaft from the front side, and then remove the lock pawl and spring.

    2. Remove the E-ring from the shaft.

  28. REMOVE MANUAL VALVE LEVER SHAFT

    A00JZ93E04

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

      Text in Illustration
      *1 Spacer
    2. A00JVRKE01

      Using a pin punch and hammer, tap out the spring pin.

      Tech Tips

      Slowly drive out the spring pin so that it does not fall into the transmission case.

    3. Pull out the manual valve lever shaft through the case and remove the manual valve lever.

  29. REMOVE MANUAL VALVE LEVER SHAFT OIL SEAL

    A00K1BEE01

    1. Using a screwdriver, pry out the 2 oil seals.

  30. REMOVE OIL PUMP ASSEMBLY

    A00JVSXE02

    1. Stand the transmission.

    2. Remove the 7 bolts from the transmission case.

    3. A00JTPHE03

      Using SST, remove the oil pump.

      SST
      09610-20012

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

    5. A00JUIVE01

      Remove the bearing race from the oil pump.

  31. REMOVE OVERDRIVE PLANETARY GEAR ASSEMBLY WITH OVERDRIVE DIRECT CLUTCH AND OVERDRIVE 1-WAY CLUTCH ASSEMBLY

    A00JXEC

    1. Remove the planetary gear with direct clutch and 1-way clutch from the transmission case.

    2. A00JXQQE01
      Text in Illustration
      *1 Bearing Race
      *2 Bearing

      Remove the bearing race and bearing.

  32. INSPECT OVERDRIVE 1-WAY CLUTCH

    A00JYTIE04

    1. Hold the overdrive direct clutch drum and turn the input shaft. Check that the input shaft can be turned clockwise freely and locks when turned counterclockwise.

      Text in Illustration
      A00JWY4 Lock
      A00JYOS Free

  33. REMOVE OVERDRIVE DIRECT CLUTCH ASSEMBLY

    A00JWU0

  34. REMOVE OVERDRIVE DIRECT CLUTCH DISC SET

    A00JU6X

    1. Using a screwdriver, pry out the snap ring from the overdrive direct clutch drum.

    2. Remove the flange, 2 discs and 2 plates.

  35. INSPECT OVERDRIVE DIRECT CLUTCH DISC

    A00JULY

    1. Replace all the discs if one of the following problems is present: 1) a disc, plate or flange is worn or burnt, 2) the lining of a disc is peeled off or discolored, or 3) the grooves or printed numbers have even a little bit of damage.

      Note

      When assembling new discs, soak them in ATF for at least 15 minutes before assembly.

  36. REMOVE OVERDRIVE DIRECT CLUTCH RETURN SPRING SUB-ASSEMBLY

    A00JW59E01

    1. Place SST on the spring retainer and compress the return spring with a press.

      SST
      09350-30020   ( 09350-07040 )

      Note

      Do not deform the spring sheet. Stop compressing when the spring sheet is lowered to a position 1 to 2 mm (0.0394 to 0.0787 in.) from the snap ring groove.

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

    3. Remove the clutch return spring.

  37. INSPECT OVERDRIVE DIRECT CLUTCH RETURN SPRING SUB-ASSEMBLY

    A00JYSR

    1. Using a vernier caliper, measure the free length of the spring together with the spring seat.

      Standard free length
      15.8 mm (0.622 in.)

      If the length is not as specified, replace the overdrive clutch return spring sub-assembly.

  38. REMOVE OVERDRIVE DIRECT CLUTCH PISTON SUB-ASSEMBLY

    A00K1UZE01

    1. Place the oil pump onto the torque converter clutch, and then place the overdrive direct clutch onto the oil pump.

    2. Hold the overdrive direct clutch piston by hand and apply compressed air (392 kPa (4.0 kgf/cm2, 57 psi)) to the oil pump to remove the overdrive direct clutch piston.

      Tech Tips

      If the piston is at an angle and cannot be removed, press down on the protruding side and apply compressed air again.

    3. Remove the 2 O-rings from the piston.

  39. INSPECT OVERDRIVE DIRECT CLUTCH PISTON SUB-ASSEMBLY

    A00K0EJE01

    1. Check that the check ball is free by shaking the piston.

    2. Check that the valve does not have leaks by applying low-pressure compressed air.

      If the result is not as specified, replace the overdrive direct clutch piston sub-assembly.

  40. INSPECT OVERDRIVE DIRECT CLUTCH DRUM SUB-ASSEMBLY

    A00JUHM

    1. Using a dial indicator, measure the inside diameter of the clutch drum bushes.

      Maximum inside diameter
      27.11 mm (1.07 in.)

      If the inside diameter is more than the maximum, replace the overdrive direct clutch drum sub-assembly.

  41. REMOVE OVERDRIVE RETAINING PLATE

    A00K0TQE01

    1. Using a screwdriver, pry out the snap ring.

    2. A00JZGWE01

      Remove the retaining plate.

  42. REMOVE OVERDRIVE 1-WAY CLUTCH OUTER RACE WITH OVERDRIVE 1-WAY CLUTCH

    A00K1TDE01

  43. REMOVE OVERDRIVE 1-WAY CLUTCH

    A00JWYD

    1. Remove the overdrive 1-way clutch from the outer race.

  44. REMOVE NO. 3 OVERDRIVE PLANETARY GEAR THRUST WASHER

    A00JUR4

  45. INSPECT OVERDRIVE PLANETARY GEAR ASSEMBLY

    A00K0ZVE01

    1. Using a dial indicator, measure the inside diameter of the planetary gear bush.

      Maximum inside diameter
      11.2 to 11.221 mm (0.441 to 0.442 in.)

      If the inside diameter is more than the maximum, replace the overdrive planetary gear assembly.

    2. A00K24SE01

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

      Standard clearance
      0.20 to 0.60 mm (0.00787 to 0.0236 in.)
      Maximum clearance
      0.65 mm (0.0256 in.)

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

  46. REMOVE OVERDRIVE PLANETARY RING GEAR WITH OVERDRIVE PLANETARY RING GEAR FLANGE

    A00JVRAE01

    1. Remove the ring gear with the overdrive planetary ring gear flange from the transmission case.

    2. A00JWIVE05
      Text in Illustration
      *1 Bearing
      *2 Bearing Race

      Remove the bearing and bearing race from the overdrive planetary ring gear.

  47. REMOVE OVERDRIVE PLANETARY RING GEAR FLANGE

    A00JZC6E01

    1. Using a screwdriver, pry out the snap ring.

    2. A00JYASE01

      Remove the ring gear flange from the overdrive planetary ring gear.

  48. REMOVE OVERDRIVE BRAKE DISC SET

    A00JY7JE01

    1. Using a screwdriver, pry out the snap ring.

    2. Remove the flange, 3 discs and 3 plates from the transmission case.

  49. INSPECT OVERDRIVE BRAKE DISC

    A00K0ZN

    1. Replace all the discs if one of the following problems is present: 1) a disc, plate or flange is worn or burnt, 2) the lining of a disc is peeled off or discolored, or 3) the grooves or printed numbers have even a little bit of damage.

      Note

      When assembling new discs, soak them in ATF for at least 15 minutes before assembly.

  50. INSPECT PISTON STROKE OF SECOND COAST BRAKE

    A00JYI1E04

    1. Using a waterproof pen, place a mark on the 2nd coast brake piston rod as shown in the illustration.

      Text in Illustration
      *1 Piston Rod
      *2 Mark
    2. A00JU41E02

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

      SST
      09240-00020
      Standard piston stroke
      1.5 to 3.0 mm (0.0591 to 0.118 in.)

      If the stroke is not as specified, inspect the brake band.

  51. REMOVE OVERDRIVE SUPPORT SUB-ASSEMBLY

    A00JUFVE02

    1. Remove the 2 bolts holding the overdrive brake assembly to the case.

    2. A00JZ1ME03

      Using SST, remove the snap ring.

      SST
      09350-30020   ( 09350-07060 )
    3. A00JYMOE03

      Using SST, remove the overdrive brake assembly.

      SST
      09350-30020   ( 09350-07020 )
    4. A00JWZQE07
      Text in Illustration
      *1 Bearing
      *2 Bearing Race

      Remove the bearing and bearing race from the overdrive brake.

  52. INSPECT PISTON OPERATION OF OVERDRIVE BRAKE

    A00JYQ0E01

    1. Place the overdrive support assembly to the direct clutch assembly.

    2. A00K1MQE01

      Apply compressed air (392 kPa (4 kgf/cm2, 57 psi)) into the oil passage and check that the overdrive brake piston moves smoothly.

  53. REMOVE OVERDRIVE BRAKE RETURN SPRING SUB-ASSEMBLY

    A00JZN1E01

    1. Place SST on the spring retainer and compress the return spring with a press.

      SST
      09350-30020   ( 09350-07030 )

    2. Using a screwdriver, pry out the snap ring.

    3. Remove the brake return spring.

  54. INSPECT OVERDRIVE BRAKE RETURN SPRING SUB-ASSEMBLY

    A00JXA7

    1. Using a vernier caliper, measure the free length of the spring together with the spring seat.

      Standard free length
      17.03 mm (0.671 in.)

      If the length is not as specified, replace the overdrive brake return spring sub-assembly.

  55. REMOVE OVERDRIVE BRAKE PISTON

    A00JYI9

    1. Place the overdrive support onto the direct clutch assembly.

    2. Hold the overdrive brake piston so that it is not slanted, and apply compressed air (392 kPa (4 kgf/cm2, 57 psi)) into the passage to remove the overdrive brake piston.

    3. A00K012E04
      Text in Illustration
      *1 O-Ring

      Remove the 2 O-rings from the overdrive brake piston.

  56. REMOVE OVERDRIVE CLUTCH DRUM OIL SEAL RING

    A00K1KYE01

    1. Remove the 2 oil seal rings from the overdrive support.

    2. A00JW4BE01

      Remove the clutch drum thrust washer from the overdrive support.

  57. REMOVE SECOND COAST BRAKE PISTON

    A00JZTME01

    1. Using SST, remove the snap ring.

      SST
      09350-30020   ( 09350-07060 )
    2. A00K05KE01

      Apply compressed air to the oil hole to remove the second coast brake cover, piston assembly and spring.

    3. Remove the 2 O-rings from the cover.

  58. REMOVE SECOND COAST BRAKE PISTON OIL SEAL RING

    A00K03FE01

  59. REMOVE SECOND COAST BRAKE PISTON ROD

    A00K1COE01

    1. Firmly press the piston down to compress the compression spring.

    2. Remove the E-ring.

    3. A00K0TBE05
      Text in Illustration
      *1 Piston Rod
      *2 Washer Plate
      *3 Spring
      *4 Piston

      Remove the piston rod, washer plate and spring from the piston.

  60. REMOVE DIRECT CLUTCH ASSEMBLY WITH FORWARD CLUTCH ASSEMBLY

    A00JUMBE01

    1. Remove the direct clutch with the forward clutch from the case.

    2. A00JTURE03
      Text in Illustration
      *1 Bearing
      *2 Bearing Race

      Remove the 2 bearings and bearing race.

  61. REMOVE FORWARD CLUTCH ASSEMBLY

    A00JXOWE03

    1. Remove the forward clutch from the direct clutch.

    2. A00K1E0E07
      Text in Illustration
      *1 Bearing
      *2 Thrust Washer
      *3 Bearing Race

      Remove the bearing, thrust washer and bearing race from the forward clutch.

  62. REMOVE DIRECT CLUTCH DISC SET

    A00K0B3E01

    1. Using a screwdriver, pry out the snap ring from the direct clutch drum.

    2. Remove the flange, 3 discs and 3 plates.

  63. INSPECT DIRECT CLUTCH DISC

    A00JW4T

    1. Replace all the discs if one of the following problems is present: 1) a disc, plate or flange is worn or burnt, 2) the lining of a disc is peeled off or discolored, or 3) the grooves or printed numbers have even a little bit of damage.

      Note

      When assembling new discs, soak them in ATF for at least 15 minutes before assembly.

  64. REMOVE DIRECT CLUTCH RETURN SPRING SUB-ASSEMBLY

    A00JXFXE02

    1. Place SST on the spring retainer and compress the return spring with a press.

      SST
      09350-30020   ( 09350-07040 )

    2. Using SST, remove the snap ring.

      SST
      09350-30020   ( 09350-07070 )

    3. Remove the return spring.

  65. INSPECT DIRECT CLUTCH RETURN SPRING SUB-ASSEMBLY

    A00K06P

    1. Using a vernier caliper, measure the free length of the spring together with the spring seat.

      Standard free length
      21.32 mm (0.839 in.)

      If the length is not as specified, replace the direct clutch return spring sub-assembly.

  66. REMOVE DIRECT CLUTCH PISTON SUB-ASSEMBLY

    A00JZJLE01

    1. Place the direct clutch drum on the overdrive support.

    2. Hold the direct clutch piston and apply compressed air (196 kPa (2.0 kgf/cm2, 28.5 psi)) to the overdrive support to remove the direct clutch piston.

      Tech Tips

      Make sure the direct clutch piston is not tilted before applying compressed air.

    3. A00JU5HE04
      Text in Illustration
      *1 O-Ring

      Using a small screwdriver, remove the 2 O-rings from the piston.

  67. INSPECT DIRECT CLUTCH PISTON SUB-ASSEMBLY

    A00JYX3E01

    1. Check that the check ball is free by shaking the piston.

    2. Check that the valve does not have leaks by applying low-pressure compressed air.

  68. INSPECT DIRECT CLUTCH DRUM SUB-ASSEMBLY

    A00JTTTE01

    1. Using a dial indicator, measure the inside diameter of the clutch drum bush.

      Standard inside diameter
      53.915 to 53.94 mm (2.123 to 2.124 in.)
      Maximum inside diameter
      53.99 mm (2.13 in.)

      If the inside diameter is more than the maximum, replace the direct clutch drum sub-assembly.

  69. FIX FORWARD CLUTCH ASSEMBLY

    A00JZ10E01

    1. Place the overdrive support on wooden blocks or equivalent to prevent the forward clutch shaft from touching the work stand.

    2. Place the forward clutch on the overdrive support.

  70. REMOVE FORWARD CLUTCH DISC SET

    A00K0NAE01

    1. Using a screwdriver, pry out the snap ring from the forward clutch drum.

    2. Remove the flange, 6 discs and 6 plates.

    3. A00K19QE01

      Remove the cushion plate.

  71. INSPECT FORWARD CLUTCH DISC

    A00K1DN

    1. Replace all the discs if one of the following problems is present: 1) a disc, plate or flange is worn or burnt, 2) the lining of a disc is peeled off or discolored, or 3) the grooves or printed numbers have even a little bit of damage.

      Note

      When assembling new discs, soak them in ATF for at least 15 minutes before assembly.

  72. REMOVE FORWARD CLUTCH RETURN SPRING SUB-ASSEMBLY

    A00K0ZRE03

    1. Place SST on the spring retainer and compress the return spring with a press.

      SST
      09350-30020   ( 09350-07040 )

    2. Using SST, remove the snap ring.

      SST
      09350-30020   ( 09350-07070 )
    3. A00K10JE04

      Remove the piston return spring.

  73. INSPECT FORWARD CLUTCH RETURN SPRING SUB-ASSEMBLY

    A00JTUN

    1. Using a vernier caliper, measure the free length of the spring together with the spring seat.

      Standard free length
      19.47 mm (0.767 in.)

      If the length is not as specified, replace the forward clutch return spring sub-assembly.

  74. REMOVE FORWARD CLUTCH PISTON SUB-ASSEMBLY

    A00K11HE01

    1. Place the forward clutch drum onto the overdrive support.

    2. Hold the forward clutch piston by hand and apply compressed air (196 kPa (2.0 kgf/cm2, 28.5 psi)) to the overdrive support to remove the forward clutch piston.

    3. A00JW0LE01

      Remove the O-ring from the forward clutch drum.

    4. A00JVA9E04
      Text in Illustration
      *1 O-Ring

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

  75. INSPECT FORWARD CLUTCH PISTON SUB-ASSEMBLY

    A00JYX3E01

    1. Check that the check ball is free by shaking the piston.

    2. Check that the valve does not have leaks by applying low-pressure compressed air.

  76. REMOVE INPUT SHAFT OIL SEAL RING

    A00JX3UE01

    1. Remove the 3 oil seal rings from the forward clutch drum groove.

  77. INSPECT INPUT SHAFT SUB-ASSEMBLY

    A00JZOBE01

    1. Using a dial indicator, measure the inside diameter of the input shaft bush.

      Standard inside diameter
      24.0 to 24.026 mm (0.945 to 0.946 in.)
      Maximum inside diameter
      24.076 mm (0.948 in.)

      If the inside diameter is more than the maximum, replace the input shaft sub-assembly.

  78. REMOVE SECOND COAST BRAKE BAND ASSEMBLY

    A00K0CXE01

    1. Using a screwdriver, pry of the 2 E-rings from the pin, and pull out the pin.

    2. A00K0HJE01

      Remove the 2nd coast brake band from the case.

  79. INSPECT SECOND COAST BRAKE BAND ASSEMBLY

    A00JZYYE04
    Text in Illustration
    *1 Printed Number

    Note


    • If the lining of the brake band is peeled off or discolored, or if any part of the printed numbers are damaged, replace the brake band.

    • When installing a new band, soak it in ATF for at least 15 minutes before installation.

  80. REMOVE FRONT PLANETARY RING GEAR SUB-ASSEMBLY

    A00JVA7E01

    1. Remove the planetary ring gear from the case.

    2. A00JYVHE05
      Text in Illustration
      *1 Bearing
      *2 Bearing Race

      Remove the 2 bearing and bearing race from the planetary ring gear.

    3. A00JYGCE04
      Text in Illustration
      *1 Wooden Block

      Place the output shaft on wooden blocks or equivalent.

  81. INSPECT FRONT PLANETARY RING GEAR SUB-ASSEMBLY

    A00K16FE01

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

      Standard inside diameter
      24.0 to 24.026 mm (0.945 to 0.946 in.)
      Maximum inside diameter
      24.076 mm (0.948 in.)

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

  82. REMOVE FRONT PLANETARY GEAR ASSEMBLY

    A00JYQVE01

    1. Remove the bearing race from the planetary gear.

    2. A00JULHE03

      Using SST, remove the snap ring.

      SST
      09350-30020   ( 09350-07070 )
    3. A00JVU7E01

      Remove the planetary gear from the case.

    4. A00K0M1E01

      Remove the bearing and bearing race from the planetary gear.

  83. INSPECT FRONT PLANETARY GEAR ASSEMBLY

    A00JXA3E01

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

      Standard clearance
      0.20 to 0.60 mm (0.00787 to 0.0236 in.)
      Maximum clearance
      0.65 mm (0.0256 in.)

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

  84. REMOVE PLANETARY SUN GEAR SUB-ASSEMBLY WITH SUN GEAR INPUT DRUM AND NO. 1 1-WAY CLUTCH ASSEMBLY

    A00JWPWE05
    Text in Illustration
    *1 Thrust Washer

    1. Remove the sun gear with the sun gear input drum and 1-way clutch from the case.

    2. Remove the thrust washer.

  85. INSPECT NO. 1 1-WAY CLUTCH ASSEMBLY

    A00JVCZE03

    1. Hold the planetary sun gear, and turn the 1-way clutch assembly. Check that the 1-way clutch hub can be turned clockwise freely and locks when turned counterclockwise.

      Text in Illustration
      A00JWY4 Lock
      A00JYOS Free

  86. REMOVE NO. 1 1-WAY CLUTCH ASSEMBLY

    A00K22TE01

  87. REMOVE NO. 1 1-WAY CLUTCH THRUST WASHER

    A00K1ACE01

  88. REMOVE SUN GEAR SHAFT OIL SEAL RING

    A00JUJVE01

    1. Remove the 2 oil seal rings from the sun gear input drum.

  89. REMOVE SUN GEAR INPUT DRUM

    A00JWXAE02

    1. Place the planetary sun gear onto a wooden block or similar object.

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

    3. Remove the input drum from the planetary sun gear.

  90. REMOVE SUN GEAR INPUT DRUM SHAFT SNAP RING

    A00JZUZE01

    1. Using a screwdriver, pry off the snap ring from the planetary sun gear.

  91. INSPECT PLANETARY SUN GEAR SUB-ASSEMBLY

    A00JZYPE01

    1. Using a dial indicator, measure the inside diameter of the planetary sun gear bushes.

      Standard inside diameter
      27.00 to 27.026 mm (1.063 to 1.064 in.)
      Maximum inside diameter
      27.076 mm (1.07 in.)

      If the inside diameter is more than the maximum, replace the planetary sun gear sub-assembly.

  92. REMOVE SECOND BRAKE DISC SET

    A00JY7GE01

    1. Using a screwdriver, pry out the snap ring.

    2. Remove the 2 flange, 5 discs and 4 plates.

  93. REMOVE SECOND BRAKE PISTON SLEEVE

    A00K04TE01

    1. Using a screwdriver, remove the sleeve.

  94. REMOVE OUTPUT SHAFT WITH REAR PLANETARY GEAR, NO. 2 1-WAY CLUTCH, FIRST AND REVERSE BRAKE DISC SET AND SECOND BRAKE DRUM

    A00JX83E03

    1. Using SST and a screwdriver, remove the snap ring.

      SST
      09350-30020   ( 09350-07060 )
    2. A00JTZZE01

      Remove the output shaft with the rear planetary gear, No. 2 1-way clutch, first and reverse brake disc set and second brake drum from transmission case.

    3. A00JZUXE01

      Remove the thrust bearing from the transmission case.

  95. REMOVE SECOND BRAKE DRUM SUB-ASSEMBLY

    A00JZ5WE01

    1. Remove the second brake drum.

  96. REMOVE NO. 4 PLANETARY CARRIER THRUST WASHER

    A00JYLFE01

  97. INSPECT SECOND BRAKE PISTON

    A00JU4RE01

    1. Check that the second brake piston moves smoothly when applying compressed air to and releasing low-pressure compressed air from the second brake drum.

  98. REMOVE SECOND BRAKE PISTON RETURN SPRING SUB-ASSEMBLY

    A00JXSVE01

    1. Place SST on the spring retainer and compress the piston return spring with a press.

      SST
      09350-30020   ( 09350-07040 )

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

      Note


      • Do not deform the spring sheet. Stop compressing when the spring sheet is lowered to a position 1 to 2 mm (0.0394 to 0.0787 in.) from the snap ring groove.

      • Do not expand the snap ring excessively.

    3. Remove the second brake piston return spring seat.

    4. A00JZ1DE03

      Remove the piston return spring.

  99. INSPECT SECOND BRAKE PISTON RETURN SPRING SUB-ASSEMBLY

    A00JVFZ

    1. Using a vernier caliper, measure the free length of the spring together with the spring seat.

      Standard free length
      16.05 mm (0.632 in.)

      If the length is not as specified, replace the second brake piston return spring sub-assembly.

  100. REMOVE SECOND BRAKE PISTON

    A00JTOUE01

    1. Hold the second brake piston by hand and apply compressed air to the 2nd brake drum to remove the 2nd brake piston.

      Tech Tips

      If the piston is at an angle and cannot be removed, press down on the protruding side and apply compressed air again.

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

  101. REMOVE FIRST AND REVERSE BRAKE DISC SET

    A00K06WE01

    1. Remove the flange, 6 plates and 6 discs.

  102. INSPECT FIRST AND REVERSE BRAKE DISC

    A00K0E3

    1. Replace all the discs if one of the following problems is present: 1) a disc, plate or flange is worn or burnt, 2) the lining of a disc is peeled off or discolored, or 3) the grooves or printed numbers have even a little bit of damage.

      Note

      When assembling new discs, soak them in ATF for at least 15 minutes before assembly.

  103. REMOVE OUTPUT SHAFT

    A00JVU3E01

  104. REMOVE PLANETARY OUTPUT SHAFT OIL SEAL RING

    A00K16LE01

  105. REMOVE REAR PLANETARY RING GEAR

    A00JWC1E01

    1. Remove the rear planetary gear from the planetary ring gear.

    2. A00JYQW

      Remove the 2 bearing race and bearing from the planetary ring gear.

    3. A00JW2AE01

      Using a screwdriver, pry out the snap ring.

    4. A00K26BE01

      Remove the planetary ring gear flange.

  106. INSPECT NO. 2 1-WAY CLUTCH

    A00JY6BE04

    1. Hold the planetary gear and turn the 1-way clutch inner race. Check that the 1-way clutch inner race can be turned counterclockwise freely and locks when turned clockwise.

      Text in Illustration
      A00JWY4 Lock
      A00JYOS Free

  107. REMOVE NO. 2 1-WAY CLUTCH

    A00JXGEE01

    1. Remove the 1-way clutch inner race from the planetary gear.

    2. A00K17PE01

      Using a screwdriver, pry out the snap ring.

    3. A00JYF2E01

      Remove the 1-way clutch from the planetary gear.

    4. A00K19RE01

      Remove the No. 2 planetary carrier thrust washer from the planetary gear.

    5. A00JU8EE01

      Remove the No. 1 planetary carrier thrust washer from the planetary gear.

  108. INSPECT REAR PLANETARY GEAR ASSEMBLY

    A00JW6IE01

    1. Using a feeler gauge, measure the thrust clearance.

      Standard clearance
      0.20 to 0.60 mm (0.00797 to 0.0236 in.)
      Maximum clearance
      0.65 mm (0.0256 in.)

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

  109. REMOVE LEAF SPRING

    A00K21ZE01

  110. REMOVE BRAKE DRUM GASKET

    A00JTXNE01

  111. REMOVE FIRST AND REVERSE BRAKE RETURN SPRING SUB-ASSEMBLY

    A00JXYCE04
    Text in Illustration
    *1 Snap Ring

    1. Place SST on the first and reverse brake return spring and compress the brake return spring.

      SST
      09350-30020   ( 09350-07050 )

    2. Using SST, remove the snap ring and brake return spring.

      SST
      09350-30020   ( 09350-07070 )

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

    A00K1GV

    1. Using a vernier caliper, measure the free length of the spring together with the spring seat.

      Standard free length
      18.182 to 18.582 mm (0.716 to 0.732 in.)

      If the length is not as specified, replace the first and reverse brake return spring sub-assembly.

  113. REMOVE NO. 2 FIRST AND REVERSE BRAKE PISTON

    A00JZVHE01

    1. Hold the No. 2 first and reverse brake piston and apply compressed air to the transmission case to remove the brake piston.

      Tech Tips

      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 brake piston.

  114. REMOVE BRAKE REACTION SLEEVE

    A00JVNME01

    1. Using SST, remove the sleeve.

      SST
      09350-30020   ( 09350-07080 )

    2. Remove the O-rings from the sleeve.

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

    A00JVX2E01

    1. Using SST, remove the brake piston.

      SST
      09350-30020   ( 09350-07090 )

    2. Remove the 2 O-rings from the brake piston.

  116. INSPECT TRANSMISSION CASE BUSH

    A00JZVNE01

    1. Using a cylinder gauge, measure the inside diameter of the transmission case rear bush.

      Standard inside diameter
      38.113 to 38.138 mm (1.5005 to 1.5014 in.)
      Maximum inside diameter
      38.19 mm (1.50 in.)

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