БЛОК АВТОМАТИЧЕСКОЙ ТРАНСМИССИИ (для моделей с 2KD-FTV) РАЗБОРКА


  1. REMOVE DRAIN (ATM) PLUG SUB-ASSEMBLY

  2. REMOVE BREATHER PLUG HOSE


    1. B007W76

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

  3. REMOVE TRANSMISSION CONTROL SHAFT LEVER LH


    1. B007QCS

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

  4. REMOVE PARK/NEUTRAL POSITION SWITCH ASSEMBLY


    1. B007QZA

      Using a screwdriver, unstake the lock washer.

    2. Remove the nut and lock washer.

    3. B007V6Y

      Remove the bolt and the park/neutral position switch.

  5. REMOVE TEMPERATURE SENSOR


    1. B007Q1E

      Remove the temperature sensor.

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

  6. REMOVE OIL COOLER TUBE UNION


    1. B007W57

      Remove the 2 oil cooler tube unions.

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

  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 EXTENSION HOUSING SUB-ASSEMBLY


    1. B007RU9

      Remove the 6 bolts.

    2. Remove the extension housing and the gasket.

  11. REMOVE EXTENSION HOUSING BUSH APPLY TUBE GASKET


    1. B007W8IE06

      Remove the bush apply tube gasket.

  12. REMOVE EXTENSION HOUSING BUSH APPLY TUBE


    1. B007W8IE07

      Remove the bush apply tube.

  13. REMOVE AUTOMATIC TRANSMISSION EXTENSION HOUSING OIL SEAL


    1. B007VXM

      Using a screwdriver, remove the extension housing oil seal.

  14. REMOVE EXTENSION HOUSING DUST (ATM) DEFLECTOR


    1. B007U20

      Mount the extension housing in a soft jaw vise.

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

  15. 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.

  16. 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.

  17. REMOVE SENSOR ROTOR (w/ Speedometer Sensor)


    1. B007PBME04

      Remove the sensor rotor and the key.

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

  18. 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.

  19. REMOVE AUTOMATIC TRANSMISSION HOUSING


    1. B007P8S

      Remove the 6 bolts.

    2. Remove the transmission housing.

  20. FIX AUTOMATIC TRANSMISSION CASE SUB-ASSEMBLY


    1. B007UL1

      Install the transmission case on the overhaul attachment.

  21. REMOVE AUTOMATIC TRANSMISSION OIL PAN SUB-ASSEMBLY


    1. B007SGC

      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 pan.

    2. B007WA4E03

      Install the blade of SST 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.

  22. INSPECT AUTOMATIC TRANSMISSION OIL PAN SUB-ASSEMBLY


    1. B007RYO

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

      Carefully lock 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 holding the oil strainer to the valve body.

    2. Remove the oil strainer and the 5 gaskets.

  24. REMOVE TRANSMISSION WIRE


    1. B007T4B

      Disconnect the 4 connectors from each shift solenoid valve.

    2. B007P9B

      Remove the bolt.

    3. Pull out the solenoid wiring from the transmission case.

    4. Remove the O-rings from the solenoid wiring.

  25. REMOVE TRANSMISSION VALVE BODY ASSEMBLY


    1. B007TO0

      Remove the 20 bolts and the valve body.

  26. REMOVE CHECK BALL BODY


    1. B007Q8Y

      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 B2 accumulator piston and the spring.

      Note


      • Blowing off the air may cause the piston to jump out. When removing the piston, hold it by hand using a waste cloth.

      • Take care not to splash ATF when air-blowing.

    2. Remove the 2 O-rings from the B2 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 C2 accumulator piston and the springs.

      Note


      • Blowing off the air may cause the piston to jump out. When removing the piston, hold it by hand using a waste cloth.

      • Take care not to splash ATF when air-blowing.

    2. Remove the 2 O-rings from the C2 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 B0 accumulator piston and the spring.

      Note


      • Blowing off the air may cause the piston to jump out. When removing the piston, hold it by hand using a waste cloth.

      • Take care not to splash ATF when air-blowing.

    2. Remove the 2 O-rings from the B0 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. B007Q8S

      Remove the 3 bolts and the parking lock pawl bracket.

  32. REMOVE PARKING LOCK ROD SUB-ASSEMBLY


    1. B007OQD

      Disconnect the parking lock rod from the manual valve lever.

  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 shaft.

  34. REMOVE MANUAL VALVE LEVER SUB-ASSEMBLY


    1. B007VCJE02

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

    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 case, and remove the manual valve lever.

  35. REMOVE MANUAL VALVE LEVER SHAFT OIL SEAL


    1. B007OPC

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

  36. REMOVE OIL PUMP ASSEMBLY


    1. B007VTQ

      Stand up the transmission.

    2. Remove the 7 bolts holding the oil pump to the transmission case.

    3. B007UENE02

      Using SST, remove the oil pump.

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

    5. B007VDM

      Remove the race from the oil pump.

  37. REMOVE OVERDRIVE PLANETARY GEAR ASSEMBLY


    1. B007U4P

      Remove the O/D planetary gear, O/D direct clutch and one-way clutch from the transmission case.

    2. B007TCH

      Remove the race and the bearing.

  38. REMOVE OVERDRIVE PLANETARY RING GEAR


    1. B007R4C

      Remove the O/D planetary ring gear from the transmission case.

    2. B007SHAE01

      Remove the bearing and the 2 races from the O/D planetary ring gear.

  39. REMOVE OVERDRIVE BRAKE PISTON


    1. B007R0KE02

      Place SST and a dial indicator onto the O/D 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
      1.75 to 2.05 mm (0.0689 to 0.0807 in.)

      If the stroke is outside the standard, inspect the discs.

  40. REMOVE OVERDRIVE BRAKE PACK


    1. B007VRG

      Using a screwdriver, remove the snap ring.

    2. B007T8Z

      Remove the O/D brake pack.

  41. INSPECT PISTON STROKE OF 2ND COST 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
      1.5 to 3.0 mm (0.059 to 0.118 in.)

      If the stroke is more than the specified, replace the piston rod.

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

      If the stroke is still more than the standard value, replace the brake band with a new one.

  42. REMOVE OVERDRIVE SUPPORT SUB-ASSEMBLY


    1. B007SH6

      Remove the 2 bolts holding the O/D support assembly from the case.

    2. B007V8QE02

      Using SST, remove the snap ring.

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

      Using SST, remove the O/D support assembly.

      SST
      09350-30020   ( 09350-07020 )
    4. B007W3DE02

      Remove the bearing and the race from the O/D support.

  43. 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 piston assembly and the spring.

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

  44. REMOVE DIRECT CLUTCH ASSEMBLY


    1. B007S1V

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

    2. Remove the bearing from the direct clutch.

  45. REMOVE FORWARD CLUTCH ASSEMBLY


    1. B007R8VE02

      Remove the direct clutch from the forward clutch.

    2. B007SWKE04

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

  46. REMOVE 2ND COAST BRAKE BAND ASSEMBLY


    1. B007V9Y

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

      Tech Tips

      Apply the 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 brake band.

    3. Remove the E-ring from the pin.

    4. B007S7A

      Remove the 2nd coast brake band from the case.

  47. REMOVE FRONT PLANETARY RING GEAR SUB-ASSEMBLY


    1. B007T4L

      Remove the front planetary ring gear from the case.

    2. B007ONL

      Remove the 2 bearings and the race from the front planetary ring gear.

    3. B007Q36

      Remove the race from the front planetary gear.

    4. B007SLXE02

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

  48. 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
      24.65 mm (0.9705 in.)

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

  49. REMOVE FRONT PLANETARY GEAR ASSEMBLY


    1. B007PT8E02

      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. B007OIK

      Remove the front planetary gear from the case.

    3. B007VIS

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

  50. INSPECT PLANETARY PINION GEAR THRUST CLEARANCE


    1. B007VG1

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

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

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

  51. REMOVE PLANETARY SUN GEAR SUB-ASSEMBLY


    1. B007V7SE02

      Remove the planetary sun gear and 1 way clutch from the case.

    2. Remove the thrust washer.

  52. INSPECT PACK CLEARANCE OF SECOND BRAKE


    1. B007URI

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

      Clearance
      0.62 to 1.98 mm (0.0244 to 0.0780 in.)

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

  53. REMOVE 2ND BRAKE PACK


    1. B007OCM

      Using a screwdriver, remove the snap ring.

    2. B007SYWE03

      Remove the 2nd brake pack.

  54. REMOVE PACK CLEARANCE OF FIRST AND REVERSE BRAKE


    1. B007U0M

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

      Clearance
      0.70 to 1.22 mm (0.0276 to 0.048 in.)

      If the clearance is non-standard, inspect the discs.

  55. REMOVE 2ND BRAKE PISTON SLEEVE


    1. B007S88

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

  56. 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 drum, the 1st and reverse brake pack and the rear planetary gear and output shaft.

    3. B007VK2

      Remove the bearing from the case.

    4. B007VTS

      Remove the 2nd brake drum.

    5. B007OUD

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

    6. B007R1V

      Remove the leaf spring.

  57. INSPECT 1ST AND REVERSE BRAKE CLUTCH DISK


    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.

  58. REMOVE BRAKE DRUM GASKET

  59. INSPECT PISTON STROKE OF 1ST AND REVERSE BRAKE


    1. B007TEL

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

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


    1. B007Q8RE02

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

      Note

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

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

    3. Remove the piston return spring.

    4. Hold the 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 1st and reverse brake piston.

  61. 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
      12.9 mm (0.508 in.)

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


    1. B007PFD

      Remove the 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 1st and reverse brake piston.

  63. REMOVE BRAKE REACTION SLEEVE


    1. B007SZQE02

      Install SST behind the reaction sleeve and gradually lift it out of the transmission case.

      SST
      09350-30020   ( 09350-07080 )

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

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


    1. B007PJHE02

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

      SST
      09350-30020   ( 09350-07090 )

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

  65. INSPECT AUTOMATIC TRANSMISSION CASE SUB-ASSEMBLY


    1. B007S1C

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

      Maximum inside diameter
      38.19 mm (1.5035 in.)

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