Automatic Transmission Unit: Disassembly
- REMOVE TRANSAXLE CASE COVER UPPER
- Remove the 2 bolts and transaxle case cover upper.
- REMOVE TRANSMISSION CONTROL SHAFT LEVER RH
- Remove the nut, spring washer and the transmission control shaft lever RH.
- REMOVE PARK/NEUTRAL POSITION SWITCH ASSEMBLY
- Using a screwdriver, unstake the lock washer.
- Remove the nut and lock washer.
- Remove the bolt and park/neutral position switch.
- REMOVE OIL COOLER TUBE UNION
- Remove the 2 oil cooler tube unions.
- Remove the O-rings from the oil cooler tube unions.
- REMOVE SPEED SENSOR
- Remove the 2 bolts and the 2 speed sensors.
- Remove the O-rings from each sensor.
- REMOVE AUTOMATIC TRANSMISSION BREATHER TUBE
- Remove the 2 bolts.
- Remove the breather tube.
- REMOVE AUTOMATIC TRANSMISSION HOUSING
- Remove the 10 bolts.
- Remove the transmission housing.
- REMOVE AUTOMATIC TRANSMISSION FLANGE YOKE ASSEMBLY
- Using a hammer and chisel, loosen the staked part of the nut.
- Remove the nut and flange yoke.
- Remove the oil seal from the flange yoke.
- REMOVE EXTENSION (ATM) HOUSING SUB-ASSEMBLY
- Remove the 6 bolts.
- Use a screwdriver to remove the extension housing sub-assembly.
- Using a snap ring expander, remove the snap ring.
- Remove the thrust needle roller bearing and the 2 bearing races.
- REMOVE RR COVER SLEEVE
- Remove the 2 washers and RR cover sleeve.
- REMOVE TRANSMISSION CASE ADAPTOR RADIAL BALL BEARING
- Remove the transmission case adaptor radial ball bearing from the extension housing sub-assembly.
- REMOVE AUTOMATIC TRANSMISSION EXTENSION HOUSING OIL SEAL
- Using a screwdriver, remove the oil seal.
- FIX AUTOMATIC TRANSMISSION CASE SUB-ASSEMBLY
- Install the transmission case on the overhaul attachment.
- REMOVE AUTOMATIC TRANSMISSION OIL PAN SUB-ASSEMBLY NOTE: Do not turn the transmission over as this will contaminate the valve body with foreign matter located at the bottom of the pan.
- Remove the over flow plug and the gasket.
- Remove the drain plug and the gasket.
- Remove the 20 bolts, oil pan and gasket.
- Examine particles in the pan.
- Remove the magnets from the oil pan. Use the removed magnets to collect any steel chips. Look carefully at the chips and particles in the pan and on the magnet to anticipate what type of wear you will find in the transaxle.
Steel (magnetic): bearing, gear and plate wear Brass (non-magnetic): bearing wear
- Remove the magnets from the oil pan. Use the removed magnets to collect any steel chips. Look carefully at the chips and particles in the pan and on the magnet to anticipate what type of wear you will find in the transaxle.
- REMOVE VALVE BODY OIL STRAINER ASSEMBLY
- Turn over the transmission.
- Remove the 4 bolts and valve body oil strainer assembly from the valve body.
- Remove the O-ring from the valve body oil strainer assembly.
- REMOVE TRANSMISSION WIRE
- Remove the 3 bolts and disconnect the 3 clamps.
- Disconnect the 9 connectors from the shift solenoid valves.
- Remove the bolt from the transmission case.
- Pull the transmission wire out of the transmission case.
- Remove the O-ring from the transmission wire.
- REMOVE TRANSMISSION VALVE BODY ASSEMBLY
- Remove the bolt, the detent spring cover and detent spring.
- Remove the 20 bolts.
- Remove the valve body assembly.
- REMOVE TRANSAXLE CASE GASKET
- Remove the 3 transaxle case gaskets.
- REMOVE BRAKE DRUM GASKET
- Remove the 3 brake drum gaskets.
- REMOVE CHECK BALL BODY
- Remove the check ball body and the spring.
- REMOVE C-2 ACCUMULATOR PISTON
- While blowing compressed air into the oil hole, remove the C-2 accumulator piston and the spring.
- Remove the 2 O-rings from the piston.NOTE: Take care as the C-3 and B-3 accumulator piston may jump out.
- REMOVE B-3 ACCUMULATOR PISTON
- Applying compressed air to the oil hole, remove the B-3 accumulator piston and the spring.
- Remove the 2 O-rings from the piston.NOTE: Take care as the C-3 accumulator piston may jump out.
- REMOVE C-3 ACCUMULATOR PISTON
- While blowing compressed air into the oil hole, remove the C-3 accumulator piston and the 2 springs.
- Remove the 2 O-rings from the piston.
- REMOVE B-1 ACCUMULATOR VALVE
- Remove the B-1 accumulator valve and the 2 springs.
- REMOVE PARKING LOCK PAWL BRACKET
- Remove the 3 bolts and the parking lock pawl bracket.
- REMOVE PARKING LOCK ROD SUB-ASSEMBLY
- Disconnect the parking lock rod from the manual valve lever.
- REMOVE PARKING LOCK PAWL SHAFT
- Pull out the parking lock pawl shaft from the front side, then remove the lock pawl and the spring.
- Remove the E-ring from the shaft.
- REMOVE MANUAL VALVE LEVER SUB-ASSEMBLY
- Using a hammer and a screwdriver, cut off the spacer and remove it from the shaft.
- Using a pin punch and a hammer, drive out the spring pin.
HINT:
Slowly drive out the spring pin so that it does not fall into the transmission case.
- Pull the manual valve lever shaft out through the case, and remove the manual valve lever.
- REMOVE MANUAL VALVE LEVER SHAFT OIL SEAL
- Using a screwdriver, remove the 2 oil seals.
- REMOVE OIL PUMP ASSEMBLY
- Remove the 10 bolts from the transmission case.
- Using a screwdriver with its tip wrapped with tape, pull out the oil pump.NOTE: Do not damage the oil pump.
- Remove the thrust bearing race No.1 from the oil pump.
- Remove the O-ring from the oil pump.
- REMOVE CLUTCH DRUM AND INPUT SHAFT
- Remove the clutch drum and input shaft from the transmission case.
- Remove the clutch drum thrust washer, 2 thrust needle roller bearings and bearing race.
- INSPECT 1 WAY NO.2 CLUTCH ASSEMBLY (See REASSEMBLY )
- REMOVE 1 WAY NO.2 CLUTCH ASSEMBLY
- Remove the 1 way No.2 clutch assembly and clutch drum thrust washer from the clutch drum and input shaft.
- REMOVE BRAKE NO.3 SNAP RING
- Using a screwdriver, remove the brake No.3 snap ring from the transmission case.
- REMOVE 2ND BRAKE DISC SET
- Remove the flange, cushion plate, 4 discs and 4 plates from the transmission case.
- INSPECT 2ND BRAKE DISC SET (See REASSEMBLY )
- REMOVE 2ND BRAKE PISTON HOLE SNAP RING
- Using SST, remove the snap ring.
SST 09350-30020 (09350-07060)
- Using SST, remove the snap ring.
- REMOVE 1 WAY CLUTCH ASSEMBLY
- Remove the 1 way clutch assembly and the planetary carrier thrust washer No.1 from the transmission case.
- REMOVE 2ND BRAKE CYLINDER
- Remove the 2nd brake cylinder from the transmission case.
- REMOVE 2ND BRAKE PISTON
- Using SST and a press, remove the 2nd brake piston snap ring.
SST 09351-40010 (09351-04060, 09351-04070)
- Remove the brake piston return spring sub-assembly No.3.
- Hold the 2nd brake piston and apply compressed air (392 kPa, 4.0 kgf/cm2 , 57 psi) to the 2nd brake cylinder to remove the 2nd brake piston.
- Remove the 2 O-rings from the 2nd brake piston.
- Using SST and a press, remove the 2nd brake piston snap ring.
- INSPECT BRAKE PISTON RETURN SPRING SUB-ASSEMBLY NO.3 (See REASSEMBLY )
- REMOVE FRONT PLANETARY GEAR ASSEMBLY
- Remove the front planetary gear assembly and the 1 way clutch inner race from the transmission case.
- Remove the thrust needle roller bearing, the thrust bearing race No.3 and the planetary carrier thrust washer No.2 from the transmission case.
- INSPECT FRONT PLANETARY GEAR ASSEMBLY (See REASSEMBLY )
- INSPECT 1 WAY CLUTCH ASSEMBLY (See REASSEMBLY )
- REMOVE FRONT PLANETARY RING GEAR
- Remove the front planetary ring gear from the transmission case.
- REMOVE CENTER PLANETARY RING GEAR
- Using a screwdriver, remove the snap ring.
- Remove the center planetary ring gear and the front planetary ring gear flange from the front planetary ring gear.
- Remove the thrust needle roller bearing from the front planetary ring gear flange.
- REMOVE BRAKE DISC NO.1
- Remove the flange, the 3 discs and the 3 plates from the transmission case.
- INSPECT BRAKE DISC NO.1 (See REASSEMBLY )
- REMOVE BRAKE PISTON RETURN SPRING SNAP RING
- Using a screwdriver, remove the brake piston return spring snap ring from the transmission case.
- REMOVE BRAKE PISTON RETURN SPRING SUB-ASSEMBLY
- Remove the brake piston return spring and the brake piston No.1 with the brake cylinder No.1 from the transmission case.
- INSPECT BRAKE PISTON RETURN SPRING SUB-ASSEMBLY (See REASSEMBLY )
- REMOVE BRAKE PISTON NO.1
- Hold the brake cylinder No.1 and apply compressed air (392 kPa, 4 kgf/cm2
, 57 psi) to the brake cylinder No.1 to remove the brake piston No.1.
HINT:
If the piston does not pop out with compressed air, lift the piston out with needle-nose pliers.
- Remove the 2 O-rings from the brake piston No.1.
- Hold the brake cylinder No.1 and apply compressed air (392 kPa, 4 kgf/cm2
, 57 psi) to the brake cylinder No.1 to remove the brake piston No.1.
- REMOVE BRAKE DISC NO.2
- Using a screwdriver, remove the brake No.2 snap ring from the transmission case.
- Remove the 2 flanges, the brake piston return spring, the 4 discs and the 3 plates from the transmission case.
- INSPECT BRAKE DISC NO.2 (See REASSEMBLY )
- INSPECT BRAKE PISTON RETURN SPRING SUB-ASSEMBLY NO.2 (See REASSEMBLY )
- REMOVE BRAKE PISTON NO.2
- Hold the brake piston No.2 and apply compressed air (392 kPa, 4 kgf/cm2
, 57 psi) to the transmission case to remove the brake piston No.2 with the cylinder.
HINT:
If the piston does not pop out with compressed air, lift the piston out with needle-nose pliers.
- Remove the piston from the cylinder.
- Remove the 2 O-rings from the brake piston No.2.
- Hold the brake piston No.2 and apply compressed air (392 kPa, 4 kgf/cm2
, 57 psi) to the transmission case to remove the brake piston No.2 with the cylinder.
- REMOVE CENTER PLANETARY GEAR ASSEMBLY
- Remove the center planetary gear assembly, the planetary sun gear and the thrust bearing race No.4 from the transmission case.
- INSPECT CENTER PLANETARY GEAR ASSEMBLY (See REASSEMBLY )
- REMOVE INTERMEDIATE SHAFT
- Using SST, remove the snap ring from the transmission case.
SST 09350-30020 (09350-07060)
- Remove the intermediate shaft with the 1 way No.3 clutch assembly from the transmission case.
- Using SST, remove the snap ring from the transmission case.
- INSPECT 1 WAY NO.3 CLUTCH ASSEMBLY (See REASSEMBLY )
- REMOVE 1 WAY NO.3 CLUTCH ASSEMBLY
- Remove the 1 way clutch No.3 assembly and the 1 way clutch inner race from the intermediate shaft.
- REMOVE REAR PLANETARY RING GEAR FLANGE SUB-ASSEMBLY
- Remove the thrust bearing race No.8, the thrust needle roller bearing, the thrust bearing race No.7 and the planetary ring gear flange from the intermediate shaft.
- INSPECT REAR PLANETARY RING GEAR FLANGE SUB-ASSEMBLY (See REASSEMBLY )
- INSPECT INTERMEDIATE SHAFT (See REASSEMBLY )
- REMOVE BRAKE PLATE STOPPER SPRING
- Remove the brake plate stopper spring from the transmission case.
- REMOVE BRAKE DISC NO.4
- Remove the sleeve, 4 plates, 4 discs and flange from the transmission case.
- INSPECT BRAKE DISC NO.4 (See REASSEMBLY )
- REMOVE REAR PLANETARY GEAR ASSEMBLY
- Remove the rear planetary gear assembly from the transmission case.
- Remove the 2 thrust needle roller bearings from the rear planetary gear assembly.
- Remove the thrust bearing race No.9 from the transmission case.
- INSPECT REAR PLANETARY GEAR ASSEMBLY (See REASSEMBLY )
- REMOVE 1ST AND REVERSE BRAKE RETURN SPRING SUB-ASSEMBLY
- Place SST on the 1st and reverse brake return spring sub-assembly and compress the brake return spring.
SST 09350-30020 (09350-07050)
- Using SST, remove the snap ring and the brake return spring.
SST 09350-30020 (09350-07070)
- Place SST on the 1st and reverse brake return spring sub-assembly and compress the brake return spring.
- INSPECT 1ST AND REVERSE BRAKE RETURN SPRING SUB-ASSEMBLY (See INSPECTION )
- REMOVE 1ST AND REVERSE BRAKE PISTON
- Hold the 1st and reverse brake piston and blow compressed air (392 kPa, 4 kgf/cm2
, 57 psi) into the transmission case to remove the brake piston.
HINT:
If the piston does not pop out with compressed air, lift the piston out with needle-nose pliers.
- Remove the brake apply tube from the piston.
- Remove the O-ring from brake piston.
- Hold the 1st and reverse brake piston and blow compressed air (392 kPa, 4 kgf/cm2
, 57 psi) into the transmission case to remove the brake piston.
- REMOVE BRAKE REACTION SLEEVE
- Using SST, remove the reaction sleeve.
SST 09350-30020 (09350-07080)
- Remove the 2 O-rings from the reaction sleeve.
- Using SST, remove the reaction sleeve.
- REMOVE BRAKE PISTON NO.4
- Using SST, remove the brake piston No.4.
SST 09350-30020 (09350-07080)
- Remove the 2 O-rings from the brake piston No.4.
- Using SST, remove the brake piston No.4.