AUTOMATIC TRANSMISSION UNIT DISASSEMBLY


  1. REMOVE TRANSMISSION CONTROL SHAFT LEVER LH

    A01E2V4E01

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

  2. REMOVE PARK/NEUTRAL POSITION SWITCH ASSEMBLY

    A01E2QYE01

    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

    A01E1JJ

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

    2. Remove the O-ring from each sensor.

  5. REMOVE AUTOMATIC TRANSAXLE BREATHER TUBE

    A01E31RE02

    1. Remove the 3 bolts.

    2. Remove the breather tube.

    3. Remove the O-ring from each tube.

  6. REMOVE AUTOMATIC TRANSMISSION HOUSING

    A01DWWI

    1. Remove the 10 bolts.

    2. Remove the transmission housing.

  7. REMOVE EXTENSION HOUSING SUB-ASSEMBLY

    A01DWXGE01

    1. Remove the 6 bolts.

    2. Remove the extension housing assembly.

      Tech Tips

      Use a brass bar and hammer to remove the extension housing assembly.

    3. Remove the gasket from the extension housing assembly.

    4. A01DW31E01

      Using a snap ring expander, remove the snap ring.

    5. Remove the thrust needle roller bearing and 2 bearing races.

  8. REMOVE EXTENSION HOUSING DUST DEFLECTOR

    A01E0BNE01

    1. Using a brass bar and hammer, remove the extension housing dust deflector.

  9. REMOVE AUTOMATIC TRANSMISSION EXTENSION HOUSING OIL SEAL

    A01E1F8E01

    1. Using SST, tap out the oil seal.

      SST
      09308-00010

  10. FIX AUTOMATIC TRANSMISSION CASE SUB-ASSEMBLY

    A01E10NE01

    1. Install the transmission case on the overhaul attachment.

  11. 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 20 bolts.

  12. INSPECT AUTOMATIC TRANSMISSION OIL PAN SUB-ASSEMBLY

    A01DXHOE01

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

    2. Carefully lock 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

  13. REMOVE VALVE BODY OIL STRAINER ASSEMBLY

    A01DW6CE01

    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.

  14. REMOVE TRANSMISSION WIRE

    A01DW6DE01

    1. Remove the ATF temperature sensor.

    2. Remove the bolt and clamp.

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

    4. A01DVV1E01

      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.

  15. REMOVE TRANSMISSION VALVE BODY ASSEMBLY

    A01E2JME01

    1. Remove the 19 bolts.

    2. Remove the valve body assembly.

  16. REMOVE TRANSAXLE CASE GASKET

    A01E00ME03

    1. Remove the 3 transaxle case gaskets.

  17. REMOVE BRAKE DRUM GASKET

    A01E0WAE01

    1. Remove the 3 brake drum gaskets.

  18. REMOVE CHECK BALL BODY

    A01DVXSE04

    1. Remove the check ball body and spring.

  19. REMOVE C-2 ACCUMULATOR PISTON

    A01DV9BE01

    1. Applying compressed air to the oil hole, and remove the C2 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.

  20. REMOVE B-3 ACCUMULATOR PISTON

    A01DV9BE01

    1. Applying compressed air to the oil hole, and remove the C2 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.

  21. REMOVE C-3 ACCUMULATOR PISTON

    A01DWQQE01

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

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

  22. REMOVE C-1 ACCUMULATOR VALVE

    A01E08YE01

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

  23. REMOVE PARKING LOCK PAWL BRACKET

    A01DX17E01

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

  24. REMOVE PARKING LOCK ROD SUB-ASSEMBLY

    A01DYW5E01

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

  25. REMOVE PARKING LOCK PAWL SHAFT

    A01DVBUE01

    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.

  26. REMOVE MANUAL VALVE LEVER SUB-ASSEMBLY

    A01DZK9E01

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

    2. A01E12AE01

      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.

  27. REMOVE MANUAL VALVE LEVER SHAFT OIL SEAL

    A01DY1KE01

    1. Using a screwdriver, remove the 2 oil seals.

  28. REMOVE OIL PUMP ASSEMBLY

    A01DVX5E01

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

    2. A01DWESE02

      Using SST, remove the oil pump.

      SST
      09350-30020   ( 09350-07020 )
    3. A01E2W2E01

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

  29. REMOVE CLUTCH DRUM AND INPUT SHAFT ASSEMBLY

    A01DY73E01

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

    2. A01DYWLE03

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

  30. INSPECT 1-WAY NO. 2 CLUTCH ASSEMBLY

    A01DYY3E01

    1. Hold the Reverse clutch hub and turn the No. 2 1-way clutch assembly

    2. The No. 2 1-way clutch assembly turns freely clockwise and locks when turned counterclockwise.

  31. REMOVE 1-WAY NO. 2 CLUTCH ASSEMBLY

    A01E0VDE01

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

  32. REMOVE NO. 3 BRAKE SNAP RING

    A01DXCUE01

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

  33. REMOVE NO. 3 BRAKE DISC

    A01DXWKE03

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

  34. INSPECT NO. 3 BRAKE DISC

    A01DVYDE01

    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.

  35. REMOVE 2ND BRAKE PISTON HOLE SNAP RING

    A01E2IRE03

    1. Using SST, remove the snap ring.

      SST
      09350-30020   ( 09350-07060 )

  36. REMOVE 1-WAY CLUTCH ASSEMBLY

    A01DZ6GE01

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

  37. REMOVE 2ND BRAKE CYLINDER

    A01DZ84E01

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

  38. REMOVE 2ND BRAKE PISTON

    A01DZPZE03

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

      SST
      09351-40010
    2. A01DXRIE01

      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. A01DWRHE03

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

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

    A01DVMQE01

    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.)

  40. REMOVE FRONT PLANETARY GEAR ASSEMBLY

    A01DX4AE01

    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. A01E254E01

      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 FRONT PLANETARY GEAR ASSEMBLY

    A01DX4AE01

    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. A01E254E01

      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.

  42. INSPECT 1-WAY CLUTCH ASSEMBLY

    A01DV4LE01

    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 the 1-way clutch inner race.

  43. REMOVE FRONT PLANETARY RING GEAR

    A01DZWCE01

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

  44. REMOVE CENTER PLANETARY RING GEAR

    A01E285E01

    1. Using a screwdriver, remove the snap ring.

    2. A01DYBAE01

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

  45. REMOVE NO. 1 BRAKE DISC

    A01E0BVE03

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

  46. INSPECT NO. 1 BRAKE DISC

    A01DVYDE01

    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.

  47. REMOVE BRAKE PISTON RETURN SPRING SNAP RING

    A01DYD1E01

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

  48. REMOVE BRAKE PISTON RETURN SPRING SUB-ASSEMBLY

    A01E1PBE01

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

  49. INSPECT BRAKE PISTON RETURN SPRING SUB-ASSEMBLY

    A01DVD6E01

    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.)

  50. REMOVE NO. 1 BRAKE PISTON

    A01DWZNE01

    1. Hold the brake piston No. 1 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.

  51. REMOVE NO. 2 BRAKE DISC

    A01E1HQE01

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

    2. A01DZO1E03

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

  52. INSPECT NO. 2 BRAKE DISC

    A01DVYDE01

    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.

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

    A01DZB6E01

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

      Standard free length
      17.45 mm (0.687 in.)

  54. REMOVE NO. 2 BRAKE PISTON

    A01E2HVE01

    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.

  55. REMOVE CENTER PLANETARY GEAR ASSEMBLY

    A01E0JQE01

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

  56. INSPECT CENTER PLANETARY GEAR ASSEMBLY

    A01DXC9E01

    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.

  57. REMOVE INTERMEDIATE SHAFT

    A01DXE0E01

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

    2. A01E17TE01

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

  58. INSPECT NO. 3 1-WAY CLUTCH ASSEMBLY

    A01E0P3E01

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

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

  59. REMOVE NO. 3 1-WAY CLUTCH ASSEMBLY

    A01DUXXE01

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

  60. REMOVE REAR PLANETARY RING GEAR FLANGE SUB-ASSEMBLY

    A01E2G3E04

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

  61. INSPECT REAR PLANETARY RING GEAR FLANGE SUB-ASSEMBLY

    A01DYYCE01

    1. Using a dial indicator, 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.

  62. INSPECT INTERMEDIATE SHAFT

    A01E24LE01

    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 anew one.

    2. A01E1IXE02

      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.)
      Standard diameter
      A
      25.912 mm (1.020 in.)
      B
      25.912 mm (1.020in.)
      C
      32.012 mm (1.260 in.)
      D
      32.012 mm (1.260 in.)

      Note

      If the outer diameter is outside the standard, replace the intermediate shaft with the new one.

  63. REMOVE BRAKE PLATE STOPPER SPRING

    A01E022E01

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

  64. REMOVE NO. 4 BRAKE DISC

    A01E0WPE03

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

  65. INSPECT NO. 4 BRAKE DISC

    A01DVYDE01

    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.

  66. REMOVE REAR PLANETARY GEAR ASSEMBLY

    A01DY9FE01

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

    2. A01E2UZE02

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

    3. A01E2FOE01

      Remove the thrust needle roller bearing from the case.

  67. INSPECT REAR PLANETARY GEAR ASSEMBLY

    A01DYYCE01

    1. Using a dial indicator, 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.

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

    A01DX9FE01

    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 the brake return spring.

      SST
      09350-30020   ( 09350-07070 )

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

    A01DYVQE01

    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.)

  70. REMOVE 1ST AND REVERSE BRAKE PISTON

    A01DX3CE01

    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 No. 2 brake piston.

  71. REMOVE BRAKE REACTION SLEEVE

    A01DZKTE04

    1. Using SST, remove the reaction sleeve.

      SST
      09350-30020   ( 09350-07080 )

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

  72. REMOVE NO. 4 BRAKE PISTON

    A01E31IE03

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

      SST
      09350-30020   ( 09350-07090 )

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