AUTOMATIC TRANSMISSION UNIT DISASSEMBLY


  1. REMOVE DRAIN PLUG SUB-ASSEMBLY

  2. REMOVE BREATHER HOSE

    A01J5HD

  3. REMOVE TRANSMISSION CONTROL SHAFT LEVER LH

    A01J4Z6E01

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

  4. REMOVE PARK/NEUTRAL POSITION SWITCH ASSEMBLY

    A01J69XE01

    1. Using a screwdriver, unstake the lock washer.

    2. Remove the nut, lock washer and grommet.

    3. Remove the bolt and 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.

  5. REMOVE ATF TEMPERATURE SENSOR


    1. A01J3KX

      Detach the sensor connector clamp from the wire harness bracket.

    2. Using a 19 mm union nut wrench, remove the ATF temperature sensor from the automatic transmission assembly.

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

    4. Remove the bolt and wire harness bracket.

  6. REMOVE OIL COOLER TUBE UNION

    A01J6X5E01

    1. Remove the 2 tube unions.

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

  7. REMOVE OVERDRIVE DIRECT CLUTCH SPEED SENSOR

    A01J581E01

    1. Remove the bolt and sensor.

    2. Remove the O-ring from the sensor.

  8. REMOVE NO. 2 VEHICLE SPEED SENSOR

    A01J6G6E01

    1. Remove the bolt and sensor.

    2. Remove the O-ring from the sensor.

  9. REMOVE AUTOMATIC TRANSMISSION HOUSING

    A01J6V0

    1. Remove the 6 bolts.

    2. Remove the transmission housing.

  10. FIX TRANSMISSION CASE

    A01J5GIE01

    1. Install the transmission case on the overhaul attachment.

  11. REMOVE TRANSFER ADAPTER REAR

    A01J3XEE01

    1. Remove the 8 bolts.

    2. Remove the rear adaptor transfer.

  12. REMOVE TRANSFER CASE ADAPTER REAR OIL SEAL

    A01J7JVE01

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

  13. REMOVE REAR TRANSFER CASE ADAPTER OIL RECEIVER


    1. A01J6RQ

      Using snap ring expander, remove the snap ring.

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

  14. REMOVE SENSOR ROTOR

    A01J3FUE01

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

    2. A01J5DX

      Remove the sensor rotor and key.

  15. REMOVE AUTOMATIC TRANSMISSION OIL PAN SUB-ASSEMBLY

    A01J4I7E01

    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. A01J4OKE04

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

      Note

      Be careful not to damage the oil pan and flange.

    3. Remove the pan by lifting the transmission case.

  16. INSPECT AUTOMATIC TRANSMISSION OIL PAN SUB-ASSEMBLY

    A01J4BUE03

    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): bushing wear.

  17. REMOVE VALVE BODY OIL STRAINER ASSEMBLY

    A01J4F0E01

    1. Remove the 4 bolts holding the oil strainer to the valve body.

    2. Remove the oil strainer and 5 gaskets.

    3. A01J5FGE01

      Pry the pipe ends with a large screwdriver and remove the pipe.

  18. REMOVE TRANSMISSION WIRE

    A01J3JG

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

    2. A01J4CBE01

      Remove the bolt and stopper plate from the case.

    3. Pull out the transmission wire from the transmission case.

    4. Remove the O-ring from the transmission wire.

  19. REMOVE TRANSMISSION VALVE BODY ASSEMBLY

    A01J5FQE01

    1. Remove the 20 bolts and valve body.

  20. REMOVE CHECK BALL BODY

    A01J43SE01

    1. Remove the check ball body and spring.

  21. REMOVE B-2 ACCUMULATOR PISTON

    A01J3DGE01

    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

    A01J3DGE02

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

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

  23. REMOVE B-0 ACCUMULATOR PISTON

    A01J4XFE01

    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

    A01J67EE01

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

    2. Remove the O-ring from the piston.

  25. REMOVE TRANSMISSION CASE PLUG

    A01J6GIE01

    1. Remove the bolt and pull out the plug.

    2. Remove the O-ring from the plug.

  26. REMOVE PARKING LOCK PAWL BRACKET

    A01J76VE01

    1. Remove the 3 bolts and bracket.

  27. REMOVE PARKING LOCK ROD

    A01J753E01

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

  28. REMOVE PARKING LOCK PAWL SHAFT

    A01J5BRE01

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

    2. Remove the E-ring from the shaft.

  29. REMOVE MANUAL VALVE LEVER SHAFT

    A01J6J6E01

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

    2. A01J7ARE01

      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.

  30. REMOVE MANUAL VALVE LEVER SHAFT OIL SEAL

    A01J4FGE01

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

  31. REMOVE OIL PUMP ASSEMBLY

    A01J4WBE01

    1. Stand up the transmission.

    2. Remove the 7 bolts from the transmission case.

    3. A01J2YFE03

      Using SST, remove the oil pump.

      SST
      09610-20012

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

    5. A01J5YDE01

      Remove the race from the oil pump.

  32. REMOVE OVERDRIVE PLANETARY GEAR ASSEMBLY AND ONE-WAY CLUTCH ASSEMBLY

    A01J78RE01

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

    2. A01J6SYE02

      Remove the race and assembled bearing and race.

  33. REMOVE OVERDRIVE PLANETARY RING GEAR

    A01J5ZTE01

    1. Remove the ring gear from the transmission case.

    2. A01J5TZE02

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

  34. INSPECT OVERDRIVE BRAKE PISTON

    A01J3NUE01

    1. Place SST and a dial indicator onto the overdrive brake piston.

      SST
      09350-30020   ( 09350-06120 )
    2. A01J5H0E01

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

      Standard piston stroke
      1.75 to 2.05 mm (0.0689 to 0.0807 in.)

      If the piston stroke is not as specified, parts may have been assembled incorrectly. Check and reassemble again.

      If the piston stroke is still outside the standard, select another flange.

      Tech Tips

      There are 7 different thicknesses for the flange.

      Standard flange thickness
      No. Specified Condition No. Specified Condition
      77 3.3 mm (0.130 in.) 81 3.8 mm (0.150 in.)
      78 3.5 mm (0.138 in.) 82 3.9 mm (0.154 in.)
      79 3.6 mm (0.142 in.) 83 4.0 mm (0.157 in.)
      80 3.7 mm (0.146 in.)

  35. REMOVE OVERDRIVE BRAKE CLUTCH DISC

    A01J6E2E01

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

    2. A01J716E04

      Remove the overdrive brake pack.

  36. INSPECT PISTON STROKE OF 2ND COAST BRAKE

    A01J3W5E01

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

    2. A01J5DTE01

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

      SST
      09240-00020
      Standard piston stroke
      1.5 to 3.0 mm (0.059 to 0.118 in.)

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

  37. REMOVE OVERDRIVE SUPPORT ASSEMBLY

    A01J795E01

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

    2. A01J3J4E01

      Using SST, remove the snap ring.

      SST
      09350-30020   ( 09350-07060 )
    3. A01J3ZUE01

      Using SST, remove the overdrive brake assembly.

      SST
      09350-30020   ( 09350-07020 )
    4. A01J5CYE05

      Remove the assembled bearing and race and race from the overdrive brake assembly.

  38. REMOVE 2ND COAST BRAKE PISTON ASSEMBLY

    A01J37BE01

    1. Using SST, remove the snap ring.

      SST
      09350-30020   ( 09350-07060 )
    2. A01J6Q9E01

      Apply compressed air to the oil hole to remove the 2nd coast brake cover, piston assembly and spring.

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

  39. REMOVE DIRECT CLUTCH ASSEMBLY

    A01J48RE01

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

    2. A01J5ENE01

      Remove the 2 bearings and races.

  40. REMOVE FORWARD CLUTCH ASSEMBLY

    A01J3YTE01

    1. Remove the direct clutch from the forward clutch.

    2. A01J56CE03

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

  41. REMOVE 2ND COAST BRAKE BAND

    A01J6K5E01

    1. Using a screwdriver, pry out the E-ring from the pin.

    2. A01J7DFE01

      Remove the 2nd coast brake band from the case.

  42. REMOVE FRONT PLANETARY RING GEAR

    A01J5CFE01

    1. Remove the planetary ring gear from the case.

    2. A01J48AE02

      Remove the assembled bearing and race, bearing and race from the planetary ring gear.

    3. A01J70WE01

      With wooden blocks or equivalent under the output shaft, stand the transmission on the output shaft.

  43. INSPECT FRONT PLANETARY RING GEAR

    A01J43RE01

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

      Maximum inside diameter
      24.65mm (0.9705 in.)

      If the inside diameter is greater than the maximum, replace the planetary ring gear.

  44. REMOVE FRONT PLANETARY GEAR

    A01J6OEE01

    1. Remove the race from the planetary gear.

    2. A01J3DOE01

      Using SST, remove the snap ring.

      SST
      09350-30020   ( 09350-07070 )
    3. A01J6RAE01

      Remove the planetary gear from the case.

    4. A01J73YE01

      Using a screwdriver, remove the bearing and race from the planetary gear.

  45. INSPECT FRONT PLANETARY PINION GEAR THRUST CLEARANCE

    A01J7NOE01

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

      Standard clearance
      0.20 to 0.60 mm (0.0079 to 0.0236 in.)
      Maximum clearance
      0.65 mm (0.0256 in.)

      If the clearance is greater than the maximum, replace the planetary gear.

  46. REMOVE PLANETARY SUN GEAR ASSEMBLY AND ONE WAY CLUTCH ASSEMBLY

    A01J6PUE01

    1. Remove the sun gear and one-way clutch from the case.

    2. Remove the thrust washer.

  47. INSPECT PACK CLEARANCE OF 2ND BRAKE

    A01J5STE01

    1. Using a feeler gauge, measure the clearance between the snap ring and flange.

      Standard clearance
      0.62 to 1.98 mm (0.0244 to 0.0780 in.)

      If the clearance is not as specified, inspect the discs.

  48. REMOVE 1ST AND REVERSE BRAKE CLUTCH DISC

    A01J4JPE01

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

    2. A01J6NAE01

      Remove the flange, plates and discs as a set.

  49. INSPECT PACK CLEARANCE OF 1ST AND REVERSE BRAKE

    A01J5BKE01

    1. Using a feeler gauge, measure the clearance between the plate and 2nd brake drum.

      Standard clearance
      0.70 to 1.22 mm (0.0276 to 0.048 in.)

      If the clearance is not as specified, select another flange.

      Tech Tips

      There are 8 different thicknesses for the flange.

      Standard flange thickness
      No. Specified Condition No. Specified Condition
      67 5.4mm (0.213 in.) 52 4.6 mm (0.181 in.)
      66 5.2 mm (0.205 in.) 53 4.4 mm (0.173 in.)
      50 5.0 mm (0.197 in.) 54 4.2 mm (0.165 in.)
      51 4.8 mm (0.189 in.) 55 4.0 mm (0.157 in.)

  50. REMOVE 2ND BRAKE PISTON SLEEVE

    A01J5K4E01

    1. Using a screwdriver, remove the sleeve.

  51. REMOVE REAR PLANETARY GEAR ASSEMBLY

    A01J7IAE01

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

      SST
      09350-30020   ( 09350-07060 )
    2. A01J65LE01

      Remove the rear planetary, 2nd brake drum, 1st and reverse brake pack, No. 2 one-way clutch and output shaft.

    3. A01J6APE01

      Remove the assembled thrust bearing and race from the case.

    4. A01J7DYE01

      Remove the 2nd brake drum.

    5. A01J5SME01

      Remove the cushion plate, flange, plates and discs of the 1st and reverse brake.

  52. REMOVE LEAF SPRING

    A01J7O8E01

  53. INSPECT 1ST AND REVERSE BRAKE CLUTCH DISC

    A01J3BPE01

    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 15 minutes.

  54. REMOVE BRAKE DRUM GASKET

    A01J4MBE01

  55. INSPECT PISTON STROKE OF 1ST AND REVERSE BRAKE

    A01J6PKE01

    1. Make sure the 1st and reverse brake pistons move smoothly when applying and releasing compressed air into the transmission case.

  56. REMOVE 1ST AND REVERSE BRAKE RETURN SPRING SUB-ASSEMBLY

    A01J39GE01

    1. Place SST on the 1st 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 )

    3. Hold the No. 2 1st and reverse brake piston by hand, and apply compressed air to the transmission case to remove the No. 2 1st and reverse brake piston.

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

    A01J31GE01

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

      Standard free length
      12.9 mm (0.508 in.)

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

  58. REMOVE NO. 2 1ST AND REVERSE BRAKE PISTON

    A01J5I4E01

    1. Hold the No. 2 1st and reverse brake piston and apply compressed air into 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.

  59. REMOVE BRAKE REACTION SLEEVE

    A01J497E01

    1. Using SST, remove the sleeve.

      SST
      09350-30020   ( 09350-07080 )

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

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

    A01J685E01

    1. Using SST, remove the brake piston.

      SST
      09350-30020   ( 09350-07090 )

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

  61. INSPECT TRANSMISSION CASE BUSHING

    A01J7KJE01

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

      Maximum inside diameter
      38.19 mm (1.5035 in.)

      If the inside diameter is greater than the maximum, replace the transmission case.