AUTOMATIC TRANSMISSION UNIT DISASSEMBLY


  1. REMOVE TRANSMISSION CONTROL SHAFT LEVER RH

    A01EPJI

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

  2. REMOVE PARK/NEUTRAL POSITION SWITCH ASSEMBLY

    A01ERWA

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

    2. Remove the nut, lock washer and bolt.

    3. Remove the park/neutral position switch.

      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.

  3. REMOVE SPEED SENSOR

    A01EPAL

    1. Remove the 2 bolts and 2 speed sensors.

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

  4. REMOVE OIL COOLER TUBE UNION (w/ Air Cooled Transmission Oil Cooler)

    A01ENW9

    1. Remove the 2 oil cooler tube unions.

    2. Remove the 2 O-rings from each oil cooler tube union.

  5. REMOVE TRANSMISSION OIL COOLER ASSEMBLY (w/o Air Cooled Transmission Oil Cooler)

    A01ENSC

    1. Remove the 3 bolts and transmission oil cooler with transmission oil thermostat.

    2. Separate the transmission oil cooler from the transmission oil thermostat.

    3. Remove the 4 O-rings.

  6. REMOVE AUTOMATIC TRANSMISSION BREATHER TUBE

    A01EQ4D

    1. Remove the 2 bolts.

    2. Remove the breather tube.

    3. Remove the O-ring from the tube.

  7. REMOVE AUTOMATIC TRANSMISSION HOUSING

    A01ESGU

    1. Remove the 14 bolts.

    2. Remove the transmission housing.

  8. REMOVE TRANSFER ADAPTER REAR

    A01ERAJ

    1. Remove the 10 bolts.

    2. Remove the rear adaptor transfer.

      Tech Tips

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

  9. REMOVE TRANSMISSION CASE ADAPTER OIL SEAL

    A01EO71

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

      Note

      Be careful not to damage the rear adaptor transfer.

      Tech Tips

      Wrap the tip of the screwdriver with tape.

  10. REMOVE TRANSFER CASE ADAPTER RADIAL BALL BEARING

    A01EQSWE01

    1. Using a screwdriver, remove the snap ring.

    2. Using SST and a press, press out the bearing.

      SST
      09950-60010   ( 09951-00650 )
      09950-70010   ( 09951-07150 )

  11. FIX AUTOMATIC TRANSMISSION CASE SUB-ASSEMBLY

    A01ERGX

    1. Install the transmission case to an overhaul attachment.

  12. REMOVE AUTOMATIC TRANSMISSION OIL PAN SUB-ASSEMBLY

    A01ENIXE01

    Note

    Do not turn the transmission over as this will contaminate the valve body with foreign matter on the bottom of the pan.


    1. Remove the drain plug, 12 bolts, oil pan and gasket.

  13. INSPECT AUTOMATIC TRANSMISSION OIL PAN SUB-ASSEMBLY

    A01EQS2E01

    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

  14. REMOVE VALVE BODY OIL STRAINER ASSEMBLY

    A01EQU2

    1. Turn over the transmission.

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

    3. Remove the O-ring from the oil strainer.

  15. REMOVE TRANSMISSION WIRE

    A01EN5YE01

    1. Remove the 2 bolts and 2 temperature sensor clamps.

    2. Disconnect the 2 ATF temperature sensors.

    3. Disconnect the 9 connectors from the solenoid valves.

    4. A01EOUM

      Remove the 2 bolts and pull out the No. 1 and No. 2 transmission wires.

    5. A01EQS9

      Remove the 2 O-rings from the transmission wire connectors.

  16. REMOVE TRANSMISSION VALVE BODY ASSEMBLY


    1. Remove the bolt, detent spring cover and detent spring.

    2. A01EOYAE02

      Remove the 19 bolts.

    3. Remove the valve body assembly.

  17. REMOVE TRANSMISSION CASE GASKET

    A01EQOL

    1. Remove the 3 gaskets.

  18. REMOVE BRAKE DRUM GASKET

    A01ERA1

    1. Remove the 3 gaskets.

  19. REMOVE CHECK BALL BODY

    A01EN2BE01

    1. Remove the check ball body and spring.

  20. REMOVE C-2 ACCUMULATOR PISTON

    A01ENQG

    1. While applying compressed air to the oil hole, remove the C-2 accumulator piston and spring.

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

      Note

      Be careful as the C-3 and B-3 accumulator pistons may jump out.

  21. REMOVE B-3 ACCUMULATOR PISTON

    A01ENQG

    1. While applying compressed air to the oil hole, remove the B-3 accumulator piston and spring.

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

      Note

      Be careful as the C-3 accumulator piston may jump out.

  22. REMOVE C-3 ACCUMULATOR PISTON

    A01ER5C

    1. While applying compressed air to the oil hole, remove the C-3 accumulator piston and spring.

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

  23. REMOVE B-1 ACCUMULATOR VALVE

    A01EMW8

    1. Remove the B-1 accumulator valve and 2 springs.

  24. REMOVE PARKING LOCK PAWL BRACKET

    A01ERC8

    1. Remove the 3 bolts and bracket.

  25. REMOVE PARKING LOCK ROD SUB-ASSEMBLY

    A01EOWLE01

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

  26. REMOVE PARKING LOCK PAWL

    A01EN91E01

    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.

  27. REMOVE MANUAL VALVE LEVER SUB-ASSEMBLY

    A01EP3HE01

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

    2. A01EQBO

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

      Tech Tips

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

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

  28. REMOVE MANUAL VALVE LEVER SHAFT OIL SEAL

    A01ESCQ

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

      Note

      Be careful not to damage the transmission case.

      Tech Tips

      Wrap the tip of the screwdriver with tape before use.

  29. REMOVE OIL PUMP ASSEMBLY

    A01ERXG

    1. Remove the 10 bolts.

    2. A01EOD1E01

      Using SST, pull out the oil pump.

      SST
      09950-40011   ( 09951-04010, 09953-04020, 09958-04011, 09952-04010, 09954-04010, 09955-04031, 09955-04031 )
    3. A01EMXO

      Remove the O-ring and 2 thrust bearing races from the oil pump.

  30. REMOVE CLUTCH DRUM AND INPUT SHAFT ASSEMBLY

    A01ENVP

    1. Remove the clutch drum and input shaft assembly from the transmission case.

    2. A01EN4N

      Remove the clutch drum thrust washer and 2 thrust needle roller bearings.

  31. INSPECT NO. 2 1-WAY CLUTCH ASSEMBLY

    A01EMV5E01

    1. Hold the reverse clutch hub and turn the 1-way clutch assembly. Check that the 1-way clutch turns freely clockwise and locks when turned counterclockwise.

  32. REMOVE NO. 2 1-WAY CLUTCH ASSEMBLY

    A01ENY3

    1. Remove the No. 2 1-way clutch and clutch drum thrust washer from the clutch drum and input shaft assembly.

  33. FIX CLUTCH DRUM AND INPUT SHAFT ASSEMBLY

    A01EPWGE01

    1. Place the oil pump onto the torque converter clutch, and then place the clutch drum and input shaft assembly onto the oil pump.

  34. REMOVE REVERSE CLUTCH HUB SUB-ASSEMBLY

    A01EOGD

    1. Using a screwdriver, remove the snap ring.

    2. A01ERML

      Remove the reverse clutch reaction sleeve and reverse clutch hub sub-assembly with the rear clutch disc set from the clutch drum.

  35. REMOVE REAR CLUTCH DISC SET

    A01ER5D

    1. Remove the cushion plate, selected reverse clutch flange, 5 discs and 4 plates from the reverse clutch hub.

    2. A01EPB0

      Remove the reverse clutch flange from the clutch drum.

  36. INSPECT REAR CLUTCH DISC

    A01ERTP

    1. Replace all 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) grooves have even a little bit of damage.

      Note

      Before assembling new discs, soak them in ATF for at least 2 hours.

  37. INSPECT REVERSE CLUTCH HUB SUB-ASSEMBLY

    A01ER12

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

      Standard inside diameter
      41.912 to 41.937 mm (1.410 to 1.411 in.)

      • If the inside diameter is more than the standard, replace the reverse clutch hub.

  38. REMOVE FORWARD CLUTCH HUB SUB-ASSEMBLY

    A01EOMO

    1. Remove the thrust needle roller bearing, forward clutch hub and No. 3 clutch hub thrust washer from the clutch drum.

  39. INSPECT FORWARD CLUTCH HUB SUB-ASSEMBLY

    A01EOZQ

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

      Standard inside diameter
      30.200 to 30.225 mm (1.189 to 1.190 in.)

      • If the inside diameter is more than the standard, replace the forward clutch hub.

  40. REMOVE COAST CLUTCH HUB SUB-ASSEMBLY WITH NO. 4 1-WAY CLUTCH ASSEMBLY

    A01EPMW

    1. Remove the 2 thrust needle roller bearings, coast clutch hub with the No. 4 1-way clutch, and thrust bearing race from the clutch drum.

  41. INSPECT NO. 4 1-WAY CLUTCH ASSEMBLY

    A01EQEIE01

    1. Hold the coast clutch hub and turn the 1-way clutch assembly. Check that the 1-way clutch turns freely clockwise and locks when turned counterclockwise.

  42. REMOVE NO. 4 1-WAY CLUTCH ASSEMBLY

    A01ES4H

    1. Separate the No. 4 1-way clutch from the coast clutch hub.

    2. Remove the No. 2 clutch hub thrust washer from the coast clutch hub.

  43. REMOVE FORWARD MULTIPLE DISC CLUTCH CLUTCH DISC SET

    A01ENH7

    1. Using a screwdriver, remove the hole snap ring.

    2. A01ENYVE01

      Remove the flange, 6 discs, 6 plates and cushion plate from the input shaft.

  44. INSPECT FORWARD MULTIPLE DISC CLUTCH CLUTCH DISC

    A01EQLE

    1. Replace all 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) grooves or printed numbers have even a little bit of damage.

      Note

      Before assembling new discs, soak them in ATF for at least 2 hours.

  45. REMOVE COAST CLUTCH DISC SET

    A01ER8I

    1. Using a screwdriver, remove the hole snap ring.

    2. A01EQHB

      Remove the flange, 4 discs and 4 plates from the input shaft.

  46. INSPECT COAST CLUTCH DISC

    A01ESBR

    1. Replace all 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) grooves or printed numbers have even a little bit of damage.

      Note

      Before assembling new discs, soak them in ATF for at least 2 hours.

  47. REMOVE INPUT SHAFT SUB-ASSEMBLY

    A01ER8S

    1. Remove the input shaft from the clutch drum.

  48. REMOVE INPUT SHAFT OIL SEAL RING

    A01EQ1C

    1. Remove the 4 oil seal rings from the input shaft.

  49. REMOVE COAST CLUTCH PISTON

    A01ER76E01

    1. Place SST on the No. 1 clutch balancer, 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. A01EO3P

      Remove the No. 1 clutch balancer and forward clutch return spring from the input shaft.

    4. A01EQA9

      Remove the O-ring from the No. 1 clutch balancer.

    5. A01EQLJ

      Hold the input shaft by hand and apply compressed air to the input shaft to remove the coast clutch piston.

  50. INSPECT FORWARD CLUTCH RETURN SPRING SUB-ASSEMBLY

    A01ERZH

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

      Standard free length
      29.65 mm (1.17 in.)

  51. REMOVE FORWARD CLUTCH PISTON SUB-ASSEMBLY

    A01EPVA

    1. Hold the input shaft by hand and apply compressed air to the input shaft to remove the forward clutch piston.

    2. A01ESLR

      Remove the O-ring from the input shaft.

  52. REMOVE DIRECT CLUTCH DISC SET

    A01ERFL

    1. Using a screwdriver, remove the 2 hole snap rings from the clutch drum.

    2. A01ENXT

      Remove the direct clutch flange, 5 discs and 5 plates from the clutch drum.

  53. INSPECT DIRECT CLUTCH DISC

    A01EPQP

    1. Replace all 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) grooves or printed numbers have even a little bit of damage.

      Note

      Before assembling new discs, soak them in ATF for at least 2 hours.

  54. REMOVE NO. 3 CLUTCH BALANCER

    A01EQVXE01

    1. Place SST on the No. 3 clutch balancer, and compress the return spring with a press.

      SST
      09380-60010   ( 09381-06020, 09381-06030, 09381-06040, 09381-06050, 09381-06080 )

    2. Using SST, remove the snap ring.

      SST
      09350-30020   ( 09350-07070 )

    3. Remove the No. 3 clutch balancer.

    4. A01EPF3

      Remove the reverse clutch return spring and O-ring from the reverse clutch piston sub-assembly.

  55. INSPECT REVERSE CLUTCH RETURN SPRING SUB-ASSEMBLY

    A01EQUY

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

      Standard free length
      21.24 mm (0.836 in.)

  56. REMOVE REVERSE CLUTCH PISTON SUB-ASSEMBLY

    A01ERV5

    1. Remove the reverse clutch piston from the clutch drum.

    2. A01EOQ8

      Remove the O-ring from the reverse clutch piston.

    3. A01ES81

      Remove the O-ring from the clutch drum.

  57. REMOVE DIRECT CLUTCH PISTON SUB-ASSEMBLY

    A01ERUBE01

    1. Place SST on the direct clutch piston, and compress the return spring with a press.

      SST
      09380-60010   ( 09381-06030, 09381-06040, 09381-06080 )

    2. Using SST, remove the snap ring.

      SST
      09350-30020   ( 09350-07070 )

    3. Place the oil pump onto the torque converter clutch, and then place the clutch drum onto the oil pump.

    4. A01ER4NE01

      Hold the direct clutch piston by hand and apply compressed air to the oil hole of the oil pump as shown in the illustration to remove the direct clutch piston with the No. 2 clutch balancer and direct clutch return spring sub-assembly.

    5. A01EPNZ

      Remove the No. 2 clutch balancer and direct clutch return spring sub-assembly from the direct clutch piston.

    6. A01EOKM

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

  58. INSPECT DIRECT CLUTCH RETURN SPRING SUB-ASSEMBLY

    A01EN55

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

      Standard free length
      19.46 mm (0.766 in.)

  59. REMOVE NO. 3 BRAKE SNAP RING

    A01EN88

    1. Using a screwdriver, remove the No. 3 brake snap ring from the transmission case.

  60. REMOVE NO. 3 BRAKE DISC SET

    A01EPOJ

    1. Remove the 2 flanges, 4 discs and 3 plates from the transmission case.

  61. INSPECT NO. 3 BRAKE DISC

    A01EQHW

    1. Replace all 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) grooves or printed numbers have even a little bit of damage.

      Note

      Before assembling new discs, soak them in ATF for at least 2 hours.

  62. REMOVE NO. 3 BRAKE PISTON HOLE SNAP RING

    A01ENNNE01

    1. Using SST, remove the snap ring.

      SST
      09350-30020   ( 09350-07060 )

  63. REMOVE NO. 3 BRAKE CYLINDER WITH NO. 3 BRAKE PISTON AND NO. 3 BRAKE PISTON RETURN SPRING SUB-ASSEMBLY

    A01EN5F

    1. Remove the No. 3 brake cylinder with the No. 3 brake piston and No. 3 brake piston return spring from the transmission case.

  64. REMOVE NO. 3 BRAKE PISTON

    A01ENFGE01

    1. Using SST and a press, compress the return spring and remove the snap ring and No. 3 brake piston return spring with a screwdriver.

      SST
      09380-60010   ( 09381-06020, 09381-06040, 09381-06060, 09381-06100, 09381-06110 )
    2. A01EPQQ

      Hold the No. 3 brake piston and apply compressed air (392 kPa, 4.0 kgf/cm2, 57 psi) to the No. 3 brake cylinder to remove the No. 3 brake piston.

    3. A01END9

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

  65. INSPECT NO. 3 BRAKE PISTON RETURN SPRING SUB-ASSEMBLY

    A01EOWX

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

      Standard free length
      15.72 mm (0.619 in.)

  66. REMOVE 1-WAY CLUTCH ASSEMBLY WITH 1-WAY CLUTCH INNER RACE SUB-ASSEMBLY

    A01ES2T

    1. Remove the 1-way clutch with 1-way clutch inner race from the transmission case.

  67. INSPECT 1-WAY CLUTCH ASSEMBLY

    A01EQBYE01

    1. Install the 1-way clutch to the 1-way clutch inner race.

    2. Hold the 1-way clutch inner race and turn the 1-way clutch. Check that the 1-way clutch turns freely counterclockwise and locks when turned clockwise.

    3. Remove the 1-way clutch from the 1-way clutch inner race.

  68. REMOVE 1-WAY CLUTCH INNER RACE SUB-ASSEMBLY

    A01EQDZ

    1. Separate the 1-way clutch inner race from the 1-way clutch and remove the No. 1 planetary carrier thrust washer.

  69. REMOVE FRONT PLANETARY GEAR ASSEMBLY

    A01EPX2

    1. Remove the front planetary gear and thrust needle roller bearing from the transmission case.

    2. A01EQUG

      Remove the No. 2 planetary carrier thrust washer, thrust bearing race and front planetary sun gear from the front planetary gear.

  70. INSPECT FRONT PLANETARY GEAR ASSEMBLY

    A01ESJB

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

      Standard clearance
      0.2 to 0.6 mm (0.00787 to 0.0236 in.)

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

    2. A01ESDF

      Using a cylinder gauge, measure the inside diameter of the front planetary gear bush.

      Standard inside diameter
      61.005 to 61.030 mm (2.402 to 2.403 in.)

      • If the inside diameter is more than the standard, replace the front planetary gear.

  71. REMOVE FRONT PLANETARY RING GEAR WITH FRONT PLANETARY RING GEAR FLANGE SUB-ASSEMBLY AND CENTER PLANETARY RING GEAR

    A01EPLT

    1. Remove the front planetary ring gear with the front planetary ring gear flange and center planetary ring gear from the transmission case.

    2. Remove the thrust needle roller bearing and thrust bearing race.

  72. REMOVE FRONT PLANETARY RING GEAR

    A01EOC9

    1. Using a screwdriver, remove the snap ring.

    2. A01ES54

      Remove the front planetary ring gear from the center planetary ring gear.

  73. REMOVE CENTER PLANETARY RING GEAR

    A01EPSL

    1. Using a screwdriver, remove the snap ring.

    2. A01EMZR

      Remove the center planetary ring gear from the front planetary ring gear flange.

  74. REMOVE NO. 1 BRAKE DISC SET

    A01EOMB

    1. Remove the flange, 4 discs and 4 plates from the transmission case.

  75. INSPECT NO. 1 BRAKE DISC

    A01EMVZ

    1. Replace all 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) grooves or printed numbers have even a little bit of damage.

      Note

      Before assembling new discs, soak them in ATF for at least 2 hours.

  76. REMOVE NO. 1 BRAKE CYLINDER WITH NO. 1 BRAKE PISTON

    A01EQDNE01

    1. Place SST on the No. 1 brake piston return spring, and compress the return spring.

      SST
      09380-60010   ( 09381-06010, 09381-06020, 09381-06050, 09381-06060, 09381-06090, 09381-06100, 09381-06110, 09381-06120 )

    2. Using a screwdriver, remove the snap ring from the transmission case.

    3. A01ENCU

      Remove the brake piston return spring and No. 1 brake piston with No. 1 brake cylinder from the transmission case.

  77. INSPECT BRAKE PISTON RETURN SPRING SUB-ASSEMBLY

    A01EN3U

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

      Standard free length
      17.05 mm (0.671 in.)

  78. REMOVE NO. 1 BRAKE PISTON

    A01ENDO

    1. Hold the No. 1 brake piston 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.

    2. A01EPZC

      Remove the 2 O-rings from the No. 1 brake piston.

  79. REMOVE NO. 2 BRAKE DISC SET

    A01ERY5E01

    1. Place SST on the No. 2 brake flange, and compress the return spring.

      SST
      09380-60010   ( 09381-06010, 09381-06020, 09381-06050, 09381-06070, 09381-06090, 09381-06120 )

    2. Using a screwdriver, remove the snap ring from the transmission case.

    3. A01ERQC

      Remove the 2 flanges, 4 discs, 3 plates and brake piston return spring from the transmission case.

  80. INSPECT NO. 2 BRAKE DISC

    A01ENDL

    1. Replace all 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) grooves or printed numbers have even a little bit of damage.

      Note

      Before assembling new discs, soak them in ATF for at least 2 hours.

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

    A01ERG7

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

      Standard free length
      22.66 mm (0.892 in.)

  82. REMOVE CENTER PLANETARY GEAR ASSEMBLY

    A01ES39

    1. Remove the center planetary gear and planetary sun gear from the transmission case.

  83. INSPECT CENTER PLANETARY GEAR ASSEMBLY

    A01EMW6

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

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

      • If the clearance is more than the standard, replace the center planetary gear assembly.

  84. REMOVE NO. 2 BRAKE CYLINDER WITH NO. 2 BRAKE PISTON

    A01EQ0G

    1. Remove the No. 2 brake cylinder with the No. 2 brake piston from the transmission case.

  85. REMOVE NO. 2 BRAKE PISTON

    A01EO26

    1. Hold the No. 2 brake piston and apply compressed air to the No. 2 brake cylinder to remove the No. 2 brake piston.

      Tech Tips

      If the piston does not pop out with compressed air, lift the piston out with needle-nose pliers.

    2. A01EP81

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

  86. REMOVE INTERMEDIATE SHAFT WITH NO. 3 1-WAY CLUTCH ASSEMBLY, REAR PLANETARY RING GEAR FLANGE AND REAR PLANETARY RING GEAR

    A01ERIZE01

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

      SST
      09350-30020   ( 09350-07060 )
    2. A01EO94

      Remove the intermediate shaft with No. 3 1-way clutch, rear planetary ring gear flange and rear planetary ring gear from the transmission case.

  87. INSPECT NO. 3 1-WAY CLUTCH ASSEMBLY

    A01EODAE01

    1. Hold the rear planetary ring gear flange and turn the 1-way clutch. Check that the 1-way clutch turns freely counterclockwise and locks when turned clockwise.

  88. REMOVE NO. 3 1-WAY CLUTCH ASSEMBLY

    A01EQ7S

    1. Remove the No. 3 1-way clutch and 1-way clutch inner race from the intermediate shaft.

  89. REMOVE REAR PLANETARY RING GEAR

    A01EQTN

    1. Remove the rear planetary ring gear with rear planetary ring gear flange, 3 thrust bearing races and thrust needle roller bearing from the intermediate shaft.

    2. A01ENKD

      Using a screwdriver, remove the snap ring.

    3. Remove the rear planetary ring gear flange from the rear planetary ring gear.

  90. INSPECT INTERMEDIATE SHAFT

    A01EO9WE01

    1. Using a dial indicator, check the intermediate shaft runout.

      Standard runout
      0.03 mm (0.00118 in.)

      If the runout is more than the standard, replace the intermediate shaft with a new one.

    2. A01EPQXE01

      Using a micrometer, check the diameter of the intermediate shaft at the positions shown in the diagram.

      Standard diameter
      A
      19.963 to 19.976 mm (0.7859 to 0.7865 in.)
      B, C
      30.150 to 30.163 mm (1.187 to 1.188 in.)
      D, E
      36.404 to 36.420 mm (1.433 to 1.434 in.)

      If the diameter is less than the standard, replace the intermediate shaft with a new one.

  91. REMOVE NO. 4 BRAKE DISC SET

    A01EOHJ

    1. Remove the 2 flanges, 7 discs and 6 plates from the transmission case.

  92. INSPECT NO. 4 BRAKE DISC


    1. A01ENUV

      Replace all 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) grooves or printed numbers have even a little bit of damage.

      Note

      Before assembling new discs, soak them in ATF for at least 2 hours.

  93. REMOVE BRAKE PLATE STOPPER SPRING

    A01ENBJ

    Note

    When removing the stopper spring, do not apply excessive force and do not deform it.

  94. REMOVE REAR PLANETARY GEAR ASSEMBLY

    A01EQBV

    1. Remove the rear planetary gear from the transmission case.

    2. A01EQJS

      Remove the 2 thrust needle roller bearings from the rear planetary gear.

    3. A01EO7L

      Remove the thrust bearing race from the transmission case.

  95. INSPECT REAR PLANETARY GEAR ASSEMBLY


    1. A01ERXB

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

      Standard clearance
      0.2 to 0.6 mm (0.00787 to 0.0236 in.)

      • If the clearance is more than the standard, replace the planetary gear assembly.

    2. A01ERG2

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

      Standard inside diameter
      20.0 to 20.025 mm (0.787 to 0.788 in.)

      • If the inside diameter is more than the standard, replace the rear planetary gear assembly.

  96. REMOVE 1ST AND REVERSE BRAKE PISTON

    A01ENJ1E01

    1. Place SST on the spring retainer and compress the brake return spring.

      SST
      09380-60010   ( 09381-06030, 09381-06040, 09381-06080, 09381-06120, 09381-06130, 09381-05040, 09381-05050 )

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

      SST
      09350-30020   ( 09350-07070 )
    3. A01ES69

      Hold the 1st and reverse brake piston and apply compressed air (392 kPa, 4.0 kgf/cm2, 57 psi) to the transmission case to remove the 1st and reverse brake piston.

      Tech Tips

      If the piston does not pop out with compressed air, lift the piston out with needle-nose pliers.

    4. A01EOE7

      Remove the 3 O-rings from the 1st and reverse brake piston.

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

    A01ESCK

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

      Standard free length
      23.54 to 23.94 mm (0.927 to 0.943 in.)