AUTOMATIC TRANSMISSION UNIT (for 1KD-FTV) DISASSEMBLY


  1. REMOVE TRANSMISSION CONTROL SHAFT LEVER LH


    1. B007QCSE01

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

  2. REMOVE PARK/NEUTRAL POSITION SWITCH ASSEMBLY


    1. B007QZA

      Using a screwdriver, unstake the lock washer.

    2. Remove the nut and the lock washer.

    3. B007V6Y

      Remove the bolt and 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.

  3. REMOVE TEMPERATURE SENSOR (w/ DPF)

    B007UKM

    1. Detach the temperature sensor connector clamp from the wire harness bracket.

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

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

  4. REMOVE TEMPERATURE SENSOR (w/o DPF)


    1. B007SZBE01

      Remove the temperature sensor.

    2. Remove the O-ring from the temperature sensor.

  5. REMOVE OIL COOLER TUBE UNION

    B007WD8E01

    1. Remove the 2 oil cooler tube unions.

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

  6. REMOVE BREATHER HOSE


    1. Remove the bolt and breather plug hose from the automatic transmission housing.

  7. REMOVE SPEEDOMETER SENSOR (w/ Speedometer Sensor)


    1. B007PWFE01

      Remove the bolt and the speedometer sensor.

    2. B007V8F

      Remove the speedometer driven gear from the speedometer sensor.

    3. Remove the O-ring from the speedometer sensor.

  8. REMOVE SPEED SENSOR NC0


    1. B007RYLE01

      Remove the bolt and the speed sensor NC0.

    2. Remove the O-ring from the speed sensor NC0.

  9. REMOVE SPEED SENSOR SP2


    1. B007VDZE01

      Remove the bolt and the speed sensor SP2.

    2. Remove the O-ring from the speed sensor SP2.

  10. REMOVE AUTOMATIC TRANSMISSION HOUSING


    1. B007Q8GE01

      Remove the 6 bolts.

    2. Remove the automatic transmission housing.

  11. FIX AUTOMATIC TRANSMISSION CASE SUB-ASSEMBLY


    1. B007UL1

      Install the automatic transmission case sub-assembly onto the overhaul attachment.

  12. REMOVE EXTENSION HOUSING SUB-ASSEMBLY


    1. B007RU9

      Remove the 6 bolts.

    2. Remove the extension housing sub-assembly and the extension housing gasket.

  13. REMOVE EXTENSION HOUSING BUSH APPLY TUBE GASKET


    1. B007W8IE06

      Remove the extension housing bush apply tube gasket.

  14. REMOVE EXTENSION HOUSING BUSH APPLY TUBE


    1. B007W8IE07

      Remove the extension housing bush apply tube.

  15. REMOVE AUTOMATIC TRANSMISSION EXTENSION HOUSING OIL SEAL


    1. B007PNWE01

      Using SST, remove the automatic transmission extension housing oil seal.

      SST
      09308-00010

  16. REMOVE EXTENSION HOUSING DUST DEFLECTOR


    1. B007U20

      Mount the extension housing sub-assembly in a soft jaw vise.

    2. Using a screwdriver and a hammer, remove the extension housing dust deflector.

  17. INSPECT EXTENSION HOUSING SUB-ASSEMBLY


    1. B007TAW

      Using a cylinder gauge, measure the inside diameter of the extension housing bushing.

      Maximum inside diameter
      40.03 mm (1.5760 in.)

      If the inside diameter is greater than the maximum, replace the extension housing.

  18. REMOVE SPEEDOMETER DRIVE GEAR (w/ Speedometer Sensor)


    1. B007SUNE01

      Using snap ring expander, remove the snap ring.

    2. Remove the speedometer drive gear and the ball.

  19. REMOVE SENSOR ROTOR (w/ Speedometer Sensor)


    1. B007PBME04

      Remove the sensor rotor and the key.

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

  20. REMOVE SENSOR ROTOR (w/o Speedometer Sensor)


    1. B007VPRE04

      Using snap ring expander, remove the rear side snap ring.

    2. Remove the sensor rotor and the key.

    3. Using snap ring expander, remove the front side snap ring.

  21. REMOVE AUTOMATIC TRANSMISSION OIL PAN SUB-ASSEMBLY


    1. B007VGAE01

      Remove the 19 bolts.

      Note

      Do not turn the transmission over as this will contaminate the valve body with any foreign matter at the bottom of the automatic transmission oil pan sub-assembly.

    2. B007WA4E04

      Insert the blade of an oil pan seal cutter between the transmission case and automatic transmission oil pan sub-assembly, and then cut through the applied sealer.

      Note

      Be careful not to damage the flanges of the automatic transmission oil pan sub-assembly and transmission case.

    3. Remove the automatic transmission oil pan sub-assembly by lifting the transmission case.

  22. INSPECT AUTOMATIC TRANSMISSION OIL PAN SUB-ASSEMBLY


    1. B007RYO

      Remove the oil cleaner magnets, and use them to collect steel particles.

      Carefully look at the foreign matter and particles in the pan and on the oil cleaner 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

  23. REMOVE VALVE BODY OIL STRAINER ASSEMBLY


    1. B007T8B

      Remove the 4 bolts.

    2. Remove the valve body oil strainer assembly and the 5 gaskets.

  24. REMOVE TRANSMISSION WIRE


    1. B007TVP

      Disconnect the 4 connectors from each shift solenoid valve.

    2. B007P9BE03

      Remove the bolt.

    3. Pull out the transmission wire from the automatic transmission case sub-assembly.

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

  25. REMOVE TRANSMISSION VALVE BODY ASSEMBLY


    1. B007TO0E01

      Remove the 20 bolts and the transmission valve body assembly.

  26. REMOVE CHECK BALL BODY


    1. B007PSZE02

      Remove the check ball body and the spring.

  27. REMOVE B-2 ACCUMULATOR PISTON


    1. B007W6A

      Applying compressed air (392 kPa, 4.0 kgf/cm2, 57 psi) to the oil hole, remove the B-2 accumulator piston and the spring.

      Note


      • The application of compressed air may cause the piston to jump out. When removing the piston, hold it using a shop rag or piece of cloth.

      • Take care not to splash ATF when applying the compressed air.

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

  28. REMOVE C-2 ACCUMULATOR PISTON


    1. B007W6A

      Applying compressed air (392 kPa, 4.0 kgf/cm2, 57 psi) to the oil hole, remove the C-2 accumulator piston and the 2 springs.

      Note


      • The application of compressed air may cause the piston to jump out. When removing the piston, hold it using a shop rag or piece of cloth.

      • Take care not to splash ATF when applying the compressed air.

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

  29. REMOVE B-0 ACCUMULATOR PISTON


    1. B007V8A

      Applying compressed air (392 kPa, 4.0 kgf/cm2, 57 psi) to the oil hole, remove the B-0 accumulator piston and the spring.

      Note


      • The application of compressed air may cause the piston to jump out. When removing the piston, hold it using a shop rag or piece of cloth.

      • Take care not to splash ATF when applying compressed air.

    2. Remove the 2 O-rings from the B-0 accumulator piston.

  30. REMOVE C-0 ACCUMULATOR PISTON


    1. B007RUI

      Applying compressed air (392 kPa, 4.0 kgf/cm2, 57 psi) to the oil hole, remove the C-0 accumulator piston and the 2 springs.

      Note


      • The application of compressed air may cause the piston to jump out. When removing the piston, hold it using a shop rag or piece of cloth.

      • Take care not to splash ATF when applying compressed air.

    2. Remove the O-ring from the C-0 accumulator piston.

  31. REMOVE PARKING LOCK PAWL BRACKET


    1. B007OG1

      Remove the 3 bolts and the parking lock pawl bracket.

  32. REMOVE PARKING LOCK ROD SUB-ASSEMBLY


    1. B007OQD

      Disconnect the parking lock rod sub-assembly from the manual valve lever sub-assembly.

  33. REMOVE PARKING LOCK PAWL SHAFT


    1. B007UWFE02

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

    2. Remove the E-ring from the parking lock pawl shaft.

  34. REMOVE MANUAL VALVE LEVER SUB-ASSEMBLY


    1. B007VCJE02

      Using a hammer and screwdriver, cut off the spacer and remove it from the manual valve lever shaft sub-assembly.

    2. B007VT7

      Using a pin punch and hammer, drive out the pin.

      Tech Tips

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

    3. Pull out the manual valve lever shaft through the automatic transmission case sub-assembly, and remove the manual valve lever sub-assembly.

  35. REMOVE MANUAL VALVE LEVER SHAFT OIL SEAL


    1. B007UZA

      Using a screwdriver, remove the 2 manual valve lever shaft oil seals.

  36. REMOVE FRONT OIL PUMP BODY SUB-ASSEMBLY


    1. B007VLZ

      Stand up the transmission.

    2. Remove the 7 bolts.

    3. B007UENE02

      Using SST, remove the front oil pump body sub-assembly.

      SST
      09350-30020   ( 09350-07020 )

    4. Remove the O-ring from the front oil pump body sub-assembly.

    5. B007TK4E02

      Remove the thrust bearing race from the front oil pump body sub-assembly.

  37. REMOVE OVERDRIVE PLANETARY GEAR ASSEMBLY


    1. B007U4P

      Remove the overdrive planetary gear, overdrive direct clutch and one-way clutch from the automatic transmission case sub-assembly.

    2. B007VMRE01

      Remove the thrust needle roller bearing and the thrust bearing race from overdrive planetary gear assembly.

  38. REMOVE OVERDRIVE PLANETARY RING GEAR


    1. B007R4C

      Remove the overdrive planetary ring gear from the automatic transmission case sub-assembly.

    2. B007V87E01

      Remove the thrust needle roller bearing and the thrust bearing race from the overdrive planetary ring gear.

  39. INSPECT OVERDRIVE BRAKE PISTON


    1. B007R0KE02

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

      SST
      09350-30020   ( 09350-06120 )
    2. B007OKD

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

      Piston stroke
      1.40 to 1.70 mm (0.0551 to 0.0669 in.)

      If the piston stroke is less than the limit, parts may be assembled incorrectly, so check and reassemble them if necessary.

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

      Tech Tips

      There are 7 different thicknesses for the flange.

      Flange thickness
      No. Thickness No. Thickness
      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.) - -

  40. REMOVE OVERDRIVE BRAKE PACK


    1. B007VRGE02

      Using a screwdriver, remove the snap ring.

      Tech Tips

      Tape up the screwdriver tip before use.

    2. B007U9ME01

      Remove the overdrive brake pack.

  41. INSPECT PISTON STROKE OF 2ND COAST BRAKE


    1. B007S3EE02

      Place a mark on the 2nd coast brake piston rod.

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

      SST
      09240-00020
      Piston rod stroke
      1.50 to 3.00 mm (0.0591 to 0.1181 in.)

      If the stroke is outside the specified range, replace the piston rod.

      Piston rod length
      78.4 mm (3.087 in.) or
      79.9 mm (3.146 in.)

      If the stroke is still outside the specified range, replace the 2nd coast brake band assembly with a new one.

  42. INSPECT OUTPUT SHAFT


    1. B007P1Q

      Using a dial indicator, measure the end play of the output shaft by hand.

      End play
      0.30 to 1.04 mm (0.0118 to 0.0409 in.)

      If the value is outside the standard range, check for improper installation.

    2. Check that the output shaft rotates smoothly.

  43. REMOVE OVERDRIVE SUPPORT SUB-ASSEMBLY


    1. B007U6V

      Remove the 2 bolts from the automatic transmission case sub-assembly.

    2. B007V8QE02

      Using SST, remove the snap ring.

      SST
      09350-30020   ( 09350-07020, 09350-07060 )
    3. B007TMYE02

      Using SST, remove the overdrive support sub-assembly.

      SST
      09350-30020   ( 09350-07020 )
    4. B007OIP

      Remove the clutch drum thrust washer from the overdrive support sub-assembly.

    5. B007VTKE01

      Remove the thrust needle roller bearing and the thrust bearing race from the overdrive support sub-assembly.

  44. REMOVE 2ND COAST BRAKE PISTON


    1. B007ODAE02

      Using SST, remove the snap ring.

      SST
      09350-30020   ( 09350-07060 )
    2. B007QQ4

      Applying compressed air (392 kPa, 4.0 kgf/cm2, 57 psi) to the oil hole, remove the 2nd coast brake cover, the 2nd coast brake piston and the spring.

    3. Remove the 2 O-rings from the 2nd coast brake cover.

  45. REMOVE DIRECT CLUTCH ASSEMBLY


    1. B007S1V

      Remove the direct clutch assembly with the forward clutch assembly from the automatic transmission case sub-assembly.

  46. REMOVE FORWARD CLUTCH ASSEMBLY


    1. B007WBEE01

      Remove the forward clutch assembly from the direct clutch assembly.

    2. B007VDQE01

      Remove the No. 2 clutch drum thrust washer, thrust needle roller bearing and thrust bearing race from the forward clutch assembly.

  47. REMOVE 2ND COAST BRAKE BAND ASSEMBLY


    1. B007V9Y

      Using a screwdriver, remove the E-ring from the pin.

      Tech Tips

      Apply grease to the E-ring and the pin before the work so that the ring does not fly out.

    2. Remove the pin from the 2nd coast brake band assembly.

    3. Remove the E-ring from the pin.

    4. B007S7A

      Remove the 2nd coast brake band assembly from the automatic transmission case sub-assembly.

  48. REMOVE FRONT PLANETARY RING GEAR SUB-ASSEMBLY


    1. B007T4L

      Remove the front planetary ring gear sub-assembly from the automatic transmission case sub-assembly.

    2. B007U03E01

      Remove the 2 thrust needle roller bearings and the thrust bearing race from the front planetary ring gear sub-assembly.

    3. B007U1P

      Remove the thrust bearing race from the front planetary gear assembly.

    4. B007SLXE02

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

  49. INSPECT FRONT PLANETARY RING GEAR SUB-ASSEMBLY


    1. B007V0M

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

      Maximum inside diameter
      24.02 mm (0.9457 in.)

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

  50. REMOVE FRONT PLANETARY GEAR ASSEMBLY


    1. B007VSCE01

      Using SST, remove the snap ring.

      SST
      09350-30020   ( 09350-07070 )

      Tech Tips

      Pushing the output shaft towards the front makes it easier to remove the snap ring.

    2. B007RW2

      Remove the front planetary gear assembly from the automatic transmission case sub-assembly.

    3. B007SOIE01

      Remove the thrust needle roller bearing and the thrust bearing race from the front planetary gear assembly.

      If necessary, using a screw driver.

  51. INSPECT PLANETARY PINION GEAR THRUST CLEARANCE


    1. B007PJ4

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

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

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

  52. REMOVE PLANETARY SUN GEAR SUB-ASSEMBLY


    1. B007V7SE03

      Remove the planetary sun gear sub-assembly and the 1 way clutch from the automatic transmission case sub-assembly.

    2. Remove the No. 4 planetary carrier thrust washer.

  53. REMOVE 1 WAY CLUTCH ASSEMBLY


    1. B007S0J

      Remove the 1 way clutch assembly from the planetary sun gear sub-assembly.

    2. B007QIA

      Remove the No. 2 planetary carrier thrust washer from the planetary sun gear sub-assembly.

  54. INSPECT 2ND BRAKE PACK CLEARANCE


    1. B007URI

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

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

      If the clearance is outside the standard, check for improper installation.

  55. REMOVE 2ND BRAKE PACK


    1. B007OCME02

      Using a screwdriver, remove the snap ring.

      Tech Tips

      Tape up the screwdriver tip before use.

    2. B007SYWE05

      Remove the 2nd brake pack.

  56. INSPECT PACK CLEARANCE OF 1ST AND REVERSE BRAKE


    1. B007U0M

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

      Standard clearance
      0.70 to 1.22 mm (0.0276 to 0.0480 in.)

      If the clearance is outside the standard range, select another flange.

      Flange thickness
      No. Thickness No. Thickness
      67 5.4 mm (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.)

  57. REMOVE 2ND BRAKE PISTON SLEEVE


    1. B007S88

      Using a screwdriver, remove the 2nd brake piston sleeve.

      Tech Tips

      Tape up the screwdriver tip before use.

  58. REMOVE REAR PLANETARY GEAR ASSEMBLY


    1. B007SDKE02

      Using SST and a screwdriver, remove the snap ring.

      SST
      09350-30020   ( 09350-07060 )
    2. B007PQ2

      Remove the 2nd brake piston assembly, the 1st and reverse brake pack, the rear planetary gear assembly and the output shaft.

    3. B007V9B

      Remove the 2nd brake piston assembly.

    4. B007TCQ

      Remove the 1st and reverse brake pack.

    5. B007R1V

      Remove the leaf spring.

  59. INSPECT 1ST AND REVERSE BRAKE CLUTCH DISC


    1. B007UPEE02

      Check if the sliding surfaces of the disc, the plate and the flange are worn or burnt. If necessary, replace them.

      Tech Tips


      • If the lining of the disc is peeled off or discolored, or even if only a part of the printed numbers is corroded, replace all discs.

      • Before assembling new discs, soak them in ATF for at least 15 minutes.

  60. REMOVE BRAKE DRUM GASKET


    1. B007UXKE01

      Remove the brake drum gasket.

  61. INSPECT PISTON STROKE OF 1ST AND REVERSE BRAKE


    1. B007TEL

      Make sure that the No. 2 1st and reverse brake piston move smoothly when applying and releasing compressed air into the transmission case.

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


    1. B007VK2

      Remove the thrust needle roller bearing from the automatic transmission case sub-assembly.

    2. B007Q8RE02

      Set SST on the spring retainer, and compress the return spring.

      SST
      09350-30020   ( 09350-07050 )

      Note

      Stop compressing when the spring retainer is lowered to a position 1 to 2 mm (0.039 to 0.078 in.) from the snap ring groove, preventing the spring retainer from being deformed.

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

    4. Remove the 1st and reverse brake return spring sub-assembly.

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


    1. B007R2FE02

      Check the return spring free length together with the spring seat.

      Standard free length
      18.39 mm (0.7240 in.)

      If the free length is shorter than the standard free length, replace the 1st and reverse brake return spring sub-assembly.

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


    1. B007PFD

      Hold the No. 2 1st and reverse brake piston by hand, and apply compressed air (392 kPa, 4.0 kgf/cm2, 57 psi) to the transmission case to remove the No. 2 1st and reverse brake piston.

      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 1st and reverse brake piston.

  65. REMOVE BRAKE REACTION SLEEVE


    1. B007SZQE02

      Install SST behind the brake reaction sleeve and gradually lift it out of the automatic transmission case sub-assembly.

      SST
      09350-30020   ( 09350-07080 )

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

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


    1. B007PJHE02

      Install SST behind the No. 1 1st and reverse brake piston and gradually lift it out of the automatic transmission case sub-assembly.

      SST
      09350-30020   ( 09350-07090 )

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

  67. INSPECT AUTOMATIC TRANSMISSION CASE SUB-ASSEMBLY


    1. B007S1C

      Using a cylinder gauge, measure the inside diameter of the automatic transmission case rear bushing.

      Maximum inside diameter
      38.13 mm (1.5012 in.)

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