Part 1

A960E AUTOMATIC TRANSMISSION / TRANSAXLE: AUTOMATIC TRANSMISSION UNIT: DISASSEMBLY

PART 1

CAUTION:
When working with FIPG material, perform the following:

* Using a razor blade and gasket scraper, remove all the old FIPG material from the gasket surfaces.
* Thoroughly clean all components to remove any loose material.
* Clean both sealing surfaces with a non-residue solvent.
* Apply FIPG in a continuous line (width approximately 1 mm (0.0393 in.)) along the sealing surface.
* Parts must be assembled within 10 minutes of application. Otherwise, the FIPG material must be removed and reapplied.
1. REMOVE TRANSMISSION CASE COVER

(a) Remove the 2 bolts and the transmission case cover.





2. REMOVE TRANSMISSION CONTROL SHAFT LEVER RH

(a) Remove the nut, spring washer and transmission control shaft lever RH.





3. REMOVE PARK/NEUTRAL POSITION SWITCH ASSEMBLY

(a) Using a screwdriver, unstake the lock washer.





(b) Remove the nut and lock washer.

(c) Remove the bolt and park/neutral position switch.

4. REMOVE TRANSMISSION OIL COOLER

(a) Remove the 3 bolts and transmission oil cooler.





(b) Remove the 2 O-rings from the transmission oil cooler.





Text in Illustration





5. REMOVE TRANSMISSION REVOLUTION SENSOR

(a) Remove the 2 bolts and the 2 transmission revolution sensors.





(b) Remove the O-ring from each sensor.

6. REMOVE AUTOMATIC TRANSMISSION BREATHER TUBE

(a) Remove the 2 bolts.





(b) Remove the breather tube.

7. REMOVE AUTOMATIC TRANSMISSION HOUSING

(a) Remove the 10 bolts.





(b) Remove the transmission housing.

8. REMOVE EXTENSION HOUSING DUST DEFLECTOR

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





NOTICE:
Be careful not to damage the extension housing.

9. REMOVE EXTENSION (ATM) HOUSING SUB-ASSEMBLY

(a) Remove the 6 bolts.





(b) Using a screwdriver, remove the extension (ATM) housing sub-assembly.





(c) Using a snap ring plier, remove the snap ring from the extension (ATM) housing sub-assembly.





(d) Remove the transmission case adaptor radial ball bearing.

(e) Using a snap ring expander, remove the snap ring.





(f) Remove the thrust needle roller bearing and the 2 thrust bearing races.

10. REMOVE AUTOMATIC TRANSMISSION EXTENSION HOUSING OIL SEAL

(a) Using a screwdriver, remove the oil seal.





11. SECURE AUTOMATIC TRANSMISSION CASE SUB-ASSEMBLY

(a) Install the transmission case on the overhaul attachment.





12. REMOVE AUTOMATIC TRANSMISSION OIL PAN SUB-ASSEMBLY

NOTICE:
Do not turn the transmission over as this will contaminate the valve body with foreign matter located at the bottom of the pan.

(a) Remove the overflow plug and the gasket.

(b) Remove the drain plug and the gasket.

(c) Remove the 20 bolts, oil pan and gasket.





(d) Examine particles in the pan.





Text in Illustration





(1) Remove the magnets from the oil pan and use them to collect any steel chips. Look carefully for the chips and particles in the pan and on the magnet to anticipate the type of wear which might be found in the transaxle.

Steel (magnetic): bearing, gear and plate wear

Brass (non-magnetic): bearing wear

13. REMOVE VALVE BODY OIL STRAINER ASSEMBLY

(a) Turn over the transmission.





(b) Remove the 4 bolts and valve body oil strainer assembly from the valve body.

(c) Remove the O-ring from the valve body oil strainer assembly.





Text in Illustration





14. REMOVE TRANSMISSION WIRE

(a) Remove the bolt and temperature sensor clamp, and separate the ATF temperature sensor.





(b) Remove the 2 bolts and disconnect the 2 clamps.





(c) Disconnect the 9 connectors from the solenoid valves.





(d) Remove the bolt and pull out the transmission wire.





(e) Remove the O-ring from the transmission wire.





Text in Illustration





15. REMOVE TRANSMISSION VALVE BODY ASSEMBLY

(a) Remove the bolt, detent spring cover and detent spring.





(b) Remove the 19 bolts.





(c) Remove the valve body assembly.

16. REMOVE TRANSAXLE CASE GASKET

(a) Remove the 3 transaxle case gaskets.





17. REMOVE BRAKE DRUM GASKET

(a) Remove the 3 brake drum gaskets.





18. REMOVE CHECK BALL BODY

(a) Remove the check ball body and the spring.





Text in Illustration





19. REMOVE C-2 ACCUMULATOR PISTON

(a) While blowing compressed air into the oil hole, remove the C-2 accumulator piston and the spring.





(b) Remove the 2 O-rings from the piston.

NOTICE:
Take care as the C-3 and B-3 accumulator pistons may jump out.

20. REMOVE B-3 ACCUMULATOR PISTON

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

(b) Remove the 2 O-rings from the piston.

NOTICE:
Take care as the C-3 accumulator piston may jump out.

21. REMOVE C-3 ACCUMULATOR PISTON

(a) While blowing compressed air into the oil hole, remove the C-3 accumulator piston and the 2 springs.





(b) Remove the 2 O-rings from the piston.

22. REMOVE B-1 ACCUMULATOR VALVE

(a) Remove the B-1 accumulator valve and the spring.





23. REMOVE PARKING LOCK PAWL BRACKET

(a) Remove the 3 bolts and the parking lock pawl bracket.





24. REMOVE PARKING LOCK ROD SUB-ASSEMBLY

(a) Disconnect the parking lock rod from the manual valve lever.





25. REMOVE PARKING LOCK PAWL SHAFT

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





Text in Illustration





(b) Remove the E-ring from the shaft.