AUTOMATIC TRANSMISSION UNIT DISASSEMBLY


  1. REMOVE TRANSMISSION CONTROL SHAFT LEVER LH

    A01J30IE01

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

  2. REMOVE PARK/NEUTRAL POSITION SWITCH ASSEMBLY

    A01J6JYE01

    1. Using a screwdriver, pry out 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 OIL COOLER TUBE UNION


    1. Remove the 2 oil cooler tube unions.

    2. Remove the O-ring from the oil cooler tube union.

  4. REMOVE SPEED SENSOR

    A01J39F

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

    2. Remove the O-ring from each sensor.

  5. REMOVE AUTOMATIC TRANSAXLE BREATHER TUBE

    A01J5JJE02

    1. Remove the 3 bolts.

    2. Remove the breather tube.

    3. Remove the O-ring from the breather tube.

  6. REMOVE AUTOMATIC TRANSMISSION HOUSING

    A01J6EI

    1. Remove the 10 bolts.

    2. Remove the transmission housing.

  7. REMOVE TRANSMISSION CASE ADAPTER SUB-ASSEMBLY

    A01J77R

  8. REMOVE TRANSMISSION CASE ADAPTER OIL SEAL

    A01J67U

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

  9. FIX AUTOMATIC TRANSMISSION CASE SUB-ASSEMBLY

    A01J533E01

    1. Install the transmission case on the overhaul attachment.

  10. 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 pan.


    1. Remove the drain plug and the 20 bolts.

  11. INSPECT AUTOMATIC TRANSMISSION OIL PAN SUB-ASSEMBLY

    A01J4BUE01

    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

  12. REMOVE VALVE BODY OIL STRAINER ASSEMBLY

    A01J6MUE01

    1. Turn over the transmission.

    2. Remove the 4 bolts holding the valve body oil strainer assembly to the valve body.

    3. Remove the O-ring form the valve body oil strainer assembly.

  13. REMOVE TRANSMISSION WIRE

    A01J331E01

    1. Remove the ATF temperature sensor.

    2. Remove the bolt and clamp.

    3. Disconnect the 7 connectors from the shift solenoid valves.

    4. A01J5VHE01

      Remove the bolt from the case.

    5. Pull the transmission wire out of the transmission case.

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

  14. REMOVE TRANSMISSION VALVE BODY ASSEMBLY

    A01J3T8E01

    1. Remove the 19 bolts.

    2. Remove the valve body assembly.

  15. REMOVE TRANSAXLE CASE GASKET

    A01J4AAE03

    1. Remove the 3 transaxle case gaskets.

  16. REMOVE BRAKE DRUM GASKET

    A01J6ZKE01

    1. Remove the 3 brake drum gaskets.

  17. REMOVE CHECK BALL BODY

    A01J3F7E04

    1. Remove the check ball body and spring.

  18. REMOVE C-2 ACCUMULATOR PISTON

    A01J3JOE01

    1. Applying compressed air to the oil hole, and 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 piston may jump out.

  19. REMOVE B-3 ACCUMULATOR PISTON

    A01J3JOE01

    1. Applying compressed air to the oil hole, and remove the C-2 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.

  20. REMOVE C-3 ACCUMULATOR PISTON

    A01J3PTE01

    1. Applying compressed air to the oil hole, and remove the B3 accumulator piston and spring.

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

  21. REMOVE C-1 ACCUMULATOR VALVE

    A01J6ELE01

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

  22. REMOVE PARKING LOCK PAWL BRACKET

    A01J5E1E01

    1. Remove the 3 bolts and parking lock pawl bracket.

  23. REMOVE PARKING LOCK ROD SUB-ASSEMBLY

    A01J4QDE01

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

  24. REMOVE PARKING LOCK PAWL SHAFT

    A01J4VLE01

    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.

  25. REMOVE MANUAL VALVE LEVER SUB-ASSEMBLY

    A01J36GE01

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

    2. A01J5U3E01

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

  26. REMOVE MANUAL VALVE LEVER SHAFT OIL SEAL

    A01J781E01

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

  27. REMOVE OIL PUMP ASSEMBLY

    A01J7BLE01

    1. Remove the 10 bolts holding the oil pump from the transmission case.

    2. A01J5DBE02

      Using SST, remove the oil pump.

      SST
      09350-30020   ( 09350-07020 )
    3. A01J4K9E01

      Remove the No. 1 thrust bearing race from the front oil pump.

  28. REMOVE CLUTCH DRUM AND INPUT SHAFT ASSEMBLY

    A01J3CBE01

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

    2. A01J3Y9E03

      Remove the clutch drum thrust washer and thrust needle roller bearing.

  29. INSPECT NO. 2 1-WAY CLUTCH ASSEMBLY

    A01J5P5E01

    1. Hold the reverse clutch hub and turn the No. 2 1-Way clutch assembly.

    2. Check that the No. 2 1-Way clutch assembly turns freely clockwise and locks when turned counterclockwise.

  30. REMOVE NO. 2 1-WAY CLUTCH ASSEMBLY

    A01J66KE01

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

  31. REMOVE NO. 3 BRAKE SNAP RING

    A01J3QAE01

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

  32. REMOVE NO. 3 BRAKE DISC

    A01J3URE03

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

  33. INSPECT NO. 3 BRAKE DISC

    A01J5V7E01

    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.

  34. REMOVE 2ND BRAKE PISTON HOLE SNAP RING

    A01J6S6E03

    1. Using SST, remove the snap ring.

      SST
      09350-30020   ( 09350-07060 )

  35. REMOVE 1-WAY CLUTCH ASSEMBLY

    A01J78ME01

    1. Remove the 1-way clutch assembly and No. 1 planetary carrier thrust washer from the case.

  36. REMOVE 2ND BRAKE CYLINDER

    A01J7CBE01

    1. Remove the 2nd brake cylinder from the case.

  37. REMOVE 2ND BRAKE PISTON

    A01J68FE03

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

      SST
      09351-40010
    2. A01J4UGE01

      Hold the 2nd brake piston and apply compressed air (392 kPa, 4.0 kgf/cm2, 57 psi) to the brake cylinder to remove the 2nd brake piston.

    3. A01J7ETE03

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

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

    A01J6I4E01

    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.)

  39. REMOVE FRONT PLANETARY GEAR ASSEMBLY

  40. INSPECT FRONT PLANETARY GEAR ASSEMBLY

    A01J6BSE01

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

      Standard clearance
      0.2 to 0.60 mm (0.008 to 0.024 in.)
      Maximum clearance
      0.65 mm (0.026 in.)

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

    2. A01J450E01

      Using a dial indicator, measure the inside diameter of the front planetary gear bushing.

      Maximum inside diameter
      57.48 mm (2.263 in.)

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

  41. INSPECT 1-WAY CLUTCH ASSEMBLY

    A01J5A1E01

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

    2. Hold the 1-way clutch inner race and turn the 1-way clutch assembly.

    3. Check that the 1-way clutch assembly turns freely counterclockwise and locks when turned clockwise.

    4. Remove the 1-way clutch assembly from 1-way clutch inner race.

  42. REMOVE FRONT PLANETARY RING GEAR

    A01J4R2E01

    1. Remove the front planetary ring gear and bearing from the transmission case.

  43. REMOVE CENTER PLANETARY RING GEAR

    A01J7P6E01

    1. Using a screwdriver, remove the snap ring.

    2. A01J5W1E01

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

  44. REMOVE NO. 1 BRAKE DISC

    A01J4RPE03

    1. Remove the flange, 3 discs and 3 plates from the case.

  45. INSPECT NO. 1 BRAKE DISC

    A01J5V7E01

    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.

  46. REMOVE BRAKE PISTON RETURN SPRING SNAP RING

    A01J4KXE01

    1. Using a screwdriver, remove the brake piston return spring snap ring from the case.

  47. REMOVE BRAKE PISTON RETURN SPRING SUB-ASSEMBLY

    A01J6UUE01

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

  48. INSPECT BRAKE PISTON RETURN SPRING SUB-ASSEMBLY

    A01J5R0E01

    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.)

  49. REMOVE NO. 1 BRAKE PISTON

    A01J4Y2E01

    1. Hold the No. 1 brake piston and apply compressed air (392 kPa, 4 kgf/cm2, 57 psi) to the transmission case 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. Remove the 2 O-rings from the No. 1 brake piston.

  50. REMOVE NO. 2 BRAKE DISC

    A01J6I7E01

    1. Using a screwdriver, remove the snap ring from the case.

    2. A01J6BWE03

      Remove the flange, brake piston return spring, 3 discs and 3 plates from the case.

  51. INSPECT NO. 2 BRAKE DISC

    A01J5V7E01

    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.

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

    A01J6GBE01

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

      Standard free length
      17.45 mm (0.687 in.)

  53. REMOVE NO. 2 BRAKE PISTON

    A01J7MLE01

    1. Hold the No. 2 brake piston and apply compressed air (392 kPa, 4 kgf/cm2, 57 psi) to the transmission case 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. Remove the 2 O-rings from the No. 2 brake piston.

  54. REMOVE CENTER PLANETARY GEAR ASSEMBLY

    A01J6VAE01

    1. Remove the center planetary gear assembly, planetary sun gear and No. 4 thrust bearing race from the case.

  55. INSPECT CENTER PLANETARY GEAR ASSEMBLY

    A01J506E01

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

      Standard clearance
      0.12 to 0.68 mm (0.005 to 0.027 in.)
      Maximum clearance
      0.73 mm (0.029 in.)

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

  56. REMOVE INTERMEDIATE SHAFT

    A01J3TAE01

    1. Using a screwdriver, remove the snap ring from the case.

    2. A01J452E01

      Remove the intermediate shaft with the No. 3 1-way clutch assembly from the case.

  57. INSPECT NO. 3 1-WAY CLUTCH ASSEMBLY

    A01J4KIE01

    1. Hold the rear planetary ring gear flange sub assembly and turn the 1-way clutch assembly.

    2. Check that the 1-way clutch assembly turns freely counterclockwise and locks when turned clockwise.

  58. REMOVE NO. 3 1-WAY CLUTCH ASSEMBLY

    A01J6ZHE01

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

  59. REMOVE REAR PLANETARY RING GEAR FLANGE SUB-ASSEMBLY

    A01J3U3E05

    1. Remove the No. 8 thrust bearing race, thrust needle roller bearing, No. 7 thrust bearing race and planetary ring gear flange from the intermediate shaft.

  60. INSPECT REAR PLANETARY RING GEAR FLANGE SUB-ASSEMBLY

    A01J5I6E01

    1. Using a caliper gauge, measure the inside diameter of the rear planetary ring gear bushing.

      Maximum inside diameter
      32.175 mm (1.267 in.)

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

  61. INSPECT INTERMEDIATE SHAFT

    A01J3CTE01

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

      Maximum runout
      0.08 mm (0.003 in.)

      Note

      If the bend exceeds the specification, replace the intermediate shaft with a new one.

    2. A01J55YE02

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

      Standard diameter
      A
      25.962 to 25.975 mm (1.022 to 1.023 in.)
      B
      25.962 to 25.975 mm (1.022 to 1.023 in.)
      C
      32.062 to 32.075 mm (1.262 to 1.263 in.)
      D
      32.062 to 32.075 mm (1.262 to 1.263 in.)
      Minimum diameter
      A
      25.912 mm (1.020 in.)
      B
      25.912 mm (1.020 in.)
      C
      32.012 mm (1.260 in.)
      D
      32.012 mm (1.260 in.)

      Note

      If the outer diameter is outside the standard or less than the minimum, replace the intermediate shaft with the new one.

  62. REMOVE BRAKE PLATE STOPPER SPRING

    A01J7NEE01

    1. Remove the brake plate stopper spring from the case.

  63. REMOVE NO. 4 BRAKE DISC

    A01J6AWE04

    1. Remove the 7 plates, 8 discs and 2 flanges from the case.

  64. INSPECT NO. 4 BRAKE DISC

    A01J5V7E01

    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.

  65. REMOVE REAR PLANETARY GEAR ASSEMBLY

    A01J6CSE01

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

    2. A01J36KE03

      Remove the No. 9 thrust bearing race and thrust needle roller bearing from the rear planetary gear assembly.

    3. A01J50ME01

      Remove the thrust needle roller bearing from the case.

  66. INSPECT REAR PLANETARY GEAR ASSEMBLY

    A01J5H2E01

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

      Standard clearance
      0.2 to 0.6 mm (0.008 to 0.024 in.)
      Maximum clearance
      0.65 mm (0.026 in.)

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

    2. A01J6S7E01

      Using a caliper gauge, measure the inside diameter of the rear planetary gear bushing.

      Maximum inside diameter
      20.075 mm (0.790 in.)

      • If the inside diameter is greater than the maximum, replace the rear planetary gear assembly.

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

    A01J4U0E01

    1. Place SST on the spring retainer 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 )

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

    A01J433E01

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

      Standard free length
      23.74 mm (0.935 in.)

  69. REMOVE 1ST AND REVERSE BRAKE PISTON

    A01J6RSE01

    1. Hold the No. 2 brake piston and apply compressed air (392 kPa, 4 kgf/cm2, 57 psi) to the transmission case 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. Remove the O-ring from the No. 2 brake piston.

  70. REMOVE BRAKE REACTION SLEEVE

    A01J60JE04

    1. Using SST, remove the reaction sleeve.

      SST
      09350-30020   ( 09350-07080 )

    2. Remove the O-ring from the reaction sleeve.

  71. REMOVE NO. 4 BRAKE PISTON

    A01J62OE03

    1. Using SST, remove the No. 4 brake piston.

      SST
      09350-30020   ( 09350-07090 )

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