1. Automatic Transmission Disassembly

Automatic Transmission Disassembly

Special Tools Required

- Mainshaft Holder Set 07PAB-0010001

1. Remove the ATF dipstick (A) and the dipstick guide tubes (B).





2. Remove the transmission range switch (C) (two bolts).

3. Pry the lock tab of the lock washer (D) on the control lever (E), then remove the bolt, the lock washer and the control lever.

4. Remove the input shaft (mainshaft) speed sensor (F), and the output shaft (countershaft) speed sensor (G).

5. Remove the ATF temperature sensor (H).

6. Remove the ATF outlet line banjo bolt (I), the line mounting bolt (J), the sealing washers (K), and the ATF outlet line (L).

7. Remove the line mounting bolt (M), the ATF filter holder (N), the ATF inlet line banjo bolt (O) and the sealing washers (P), and remove the ATF inlet line/ATF hose/ ATF filter (Q).

8. Remove the ATF filter bracket (R), and remove the third shaft end cover (S), the mainshaft end cover (T), and the end covers (U) (two).

9. Remove transmission fluid pressure switch A (2nd clutch) (V) and the sealing washer.

10. Remove transmission fluid pressure switch D (5th clutch) (W) and the sealing washer.

11. Remove transmission fluid pressure switch C (4th clutch) (X) and the sealing washer.

12. Remove shift solenoid valve C (Y).

13. Remove the secondary valve body (Z). Remove the ATF pipes (AA), and the gasket (BB).

NOTE: Do not disassemble the secondary valve body. If any problem occurs, replace the assembly.

14. Install the mainshaft holder onto the mainshaft.






15. Cut the lock tab (A) of the mainshaft locknut (B) and the third shaft locknut using a chisel (C).

NOTE:

- Keep all of the chiseled particles out of the transmission.

- The illustration shows mainshaft locknut.





16. Remove the locknuts (A) from the mainshaft (B) and the third shaft (C).

NOTE: The third shaft locknut has left-hand threads.





17. Pry the lock washers (D), and remove them.

NOTE: Keep all of the particles out of the transmission.

18. Remove the 10 x 1.25 mm transmission housing mounting bolts (A) (14 bolts), the 8 x 1.25 mm transmission housing mounting bolts (B) (16 bolts), and transmission hanger C.






19. While expanding the snap ring of the countershaft bearing with snap ring pliers, lift the transmission housing.






20. Release the snap ring pliers, and remove the transmission housing (D), the two dowel pins (E), and the gasket.

21. Remove transmission hanger A (F) and transmission hanger B (G).

22. Remove the joint pipes (H) (two).

23. Remove the ATF strainer (I) (two bolts).

24. Remove the 10 x 70 mm ATF feed pipe (J) and the ATF lubrication pipe (K) from the regulator valve body.

25. Remove the mainshaft holder from the mainshaft.

26. Pry the lock tab of the lock washer (L) on the shift fork (M), then remove the bolt and the lock washer.

27. Remove the reverse gear (N), the reverse selector hub (O), the shift fork, and the baffle plate (P) together.

28. Remove the mainshaft (Q), the countershaft (R), the secondary shaft (S), and the idler gear shaft (T) together, and remove the needle bearing (U) from the torque converter housing.






29. Remove the third shaft (V).

30. Remove the parking holder (W).

31. Remove the detent arm (X), the detent arm shaft (Y), the detent arm spring (Z), and the selector control shaft (AA).

32. Remove the differential assembly (BB).

33. Remove the transfer output shaft (CC).

34. Remove the cooler retainer cap (A).






35. Remove the 3rd air check valve (B) and the 6th air check valve (C) from the stator shaft support.

36. Remove the stator shaft support (D) (four bolts), the stator shaft (E), the stator shaft stop (F) and the dowel pins (G) (two).

37. Remove the manual valve body (H) (seven bolts), the dowel pins (I) (two), and the manual separator plate (J).

NOTE: Do not disassemble the manual valve body. If any problem occurs, replace the assembly.

38. Remove the regulator valve body (K) (eight bolts), the dowel pins (L) (two), and the regulator separator plate (M).

NOTE: Do not disassemble the regulator valve body. If any problem occurs, replace the assembly.

39. Remove the 4th/reverse air check valve (N) with the main valve body.

40. Remove the main valve body (O) (eight bolts). Do not let the check balls (P) (two) fall out.

NOTE: Do not disassemble the main valve body. If any problem occurs, replace the assembly.

41. Remove the ATF pump driven gear shaft (Q), then remove the ATF pump driven gear (R), and the ATF pump drive gear (S).

42. Remove the dowel pins (T) (two) and the main separator plate (U).

43. Remove the ATF magnet (V), clean it, then reinstall it in the torque converter housing.

44. Remove the 2nd air check valve (W) and the 5th air check valve (X) from the torque converter housing.

45. Remove the O-ring (Y) from the stator shaft, and replace it with a new O-ring when reassembling the transmission.

46. Remove the O-ring from the ATF strainer, and replace it with a new O-ring when reassembling the transmission.

47. Clean the inlet opening (A) of the ATF strainer (B) thoroughly with compressed air, then check that it is good condition and that the inlet opening is not clogged.






48. Check the ATF strainer for clogs, debris, or damage. If the strainer is clogged or damaged, replace it.