Part 2

AA80F AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION UNIT: DISASSEMBLY

30. REMOVE OVERDRIVE DIRECT CLUTCH PISTON SUB-ASSEMBLY





(a) Place SST on the No. 3 clutch balancer and compress the overdrive clutch return spring with a press.

SST : 09380-50010

(b) Using SST, remove the snap ring.

SST : 09350-30020

09350-07070

(c) Remove the No. 3 clutch balancer and overdrive clutch return spring.





(d) Hold the overdrive direct clutch piston and apply compressed air to the oil hole of the drum to remove the overdrive direct clutch piston.





Text in Illustration





(e) Remove the O-ring from the No. 3 clutch balancer.

(f) Remove the O-ring from the overdrive direct clutch piston sub-assembly.

(g) Remove the O-ring from the overdrive direct clutch drum sub-assembly.

31. INSPECT OVERDRIVE CLUTCH RETURN SPRING SUB-ASSEMBLY Automatic Transmission Unit

32. INSPECT OVERDRIVE DIRECT CLUTCH DRUM SUB-ASSEMBLY Automatic Transmission Unit

33. REMOVE FORWARD MULTIPLE DISC CLUTCH SUB-ASSEMBLY WITH FRONT PLANETARY RING GEAR





(a) Remove the forward multiple disc clutch with front planetary ring gear, the thrust needle roller bearing and the thrust bearing race from the transmission case.

(b) Using needle-nose pliers, detach the snap ring and remove the front planetary ring gear from the forward clutch drum.





34. REMOVE FORWARD MULTIPLE CLUTCH DISC SET

(a) Using a screwdriver, remove the snap ring.





Text in Illustration





HINT
Tape the screwdriver tip before use.

(b) Remove the forward clutch flange, 6 forward multiple disc clutch clutch discs, 6 forward multiple disc clutch clutch plates and clutch cushion plate.

35. INSPECT FORWARD MULTIPLE DISC CLUTCH CLUTCH DISC Automatic Transmission Unit

36. REMOVE FORWARD CLUTCH PISTON





(a) Place SST on the No. 1 clutch balancer and compress the forward clutch return spring with a press.

SST : 09380-50010

(b) Using SST, remove the snap ring.

SST : 09350-30020

09350-07070

(c) Remove the No. 1 clutch balancer and forward clutch return spring sub-assembly from the forward clutch drum sub-assembly.





(d) Remove the O-ring from the No. 1 clutch balancer.

(e) Hold the forward clutch piston and apply compressed air to the oil hole of the drum to remove the forward clutch piston.





Text in Illustration





(f) Remove the 2 O-rings from the forward clutch piston.

37. INSPECT FORWARD CLUTCH RETURN SPRING SUB-ASSEMBLY Automatic Transmission Unit

38. INSPECT FORWARD CLUTCH DRUM SUB-ASSEMBLY Automatic Transmission Unit

39. REMOVE MULTIPLE DISC CLUTCH CLUTCH HUB





(a) Remove the multiple disc clutch clutch hub from the transmission case.

(b) Remove the thrust bearing race and thrust needle roller bearing from the transmission case.

40. REMOVE SUN GEAR INPUT DRUM SUB-ASSEMBLY





(a) Remove the sun gear input drum, thrust needle roller bearing and thrust bearing race from the transmission case.

41. INSPECT SUN GEAR INPUT DRUM SUB-ASSEMBLY Automatic Transmission Unit

42. REMOVE REAR PLANETARY SUN GEAR ASSEMBLY





(a) Remove the rear planetary sun gear assembly and thrust bearing race from the transmission case.

43. REMOVE 1-WAY CLUTCH OUTER RACE WITH NO. 1 1-WAY CLUTCH





(a) Using SST, remove the snap ring from the transmission case.

SST : 09350-30020

09350-07060

(b) Remove the 1-way clutch outer race with No. 1 1-way clutch.





44. INSPECT REAR PLANETARY SUN GEAR ASSEMBLY Automatic Transmission Unit

45. REMOVE REAR PLANETARY GEAR ASSEMBLY





(a) Remove the thrust needle roller bearing, rear planetary gear assembly and thrust bearing race from the transmission case.

46. INSPECT NO. 1 1-WAY CLUTCH Automatic Transmission Unit

47. REMOVE NO. 1 1-WAY CLUTCH





(a) Remove the 2 snap rings from the 1-way clutch outer race.

48. INSPECT REAR PLANETARY GEAR ASSEMBLY Automatic Transmission Unit

49. REMOVE NO. 2 BRAKE DISC SET

(a) Remove the brake plate, 4 No. 2 brake discs, 3 No. 2 brake plates and No. 2 brake flange.

50. INSPECT NO. 2 BRAKE DISC Automatic Transmission Unit

51. REMOVE DIRECT CLUTCH DRUM SUB-ASSEMBLY WITH REAR PLANETARY RING GEAR AND OUTPUT SHAFT SUB-ASSEMBLY





(a) Remove the 2 thrust needle roller bearings, the 2 thrust bearing races and the direct clutch drum with rear planetary ring gear and output shaft from the transmission case.

52. REMOVE REAR PLANETARY RING GEAR

(a) Using needle-nose pliers, detach the snap ring and disconnect the rear planetary ring gear from the output shaft.





53. DISCONNECT DIRECT CLUTCH DRUM SUB-ASSEMBLY





(a) Disconnect the direct clutch drum from the output shaft and remove the thrust needle roller bearing and thrust bearing race from the output shaft.

(b) Remove the 3 oil seal rings from the output shaft.





(c) Remove the 2 oil seal rings from the direct clutch drum.





54. REMOVE NO. 2 CLUTCH DISC SET

(a) Using a screwdriver, remove the snap ring, direct clutch flange, 6 No. 2 clutch discs and 6 No. 2 clutch plates from the direct clutch drum.





Text in Illustration





HINT
Tape the screwdriver tip before use.

55. INSPECT NO. 2 CLUTCH DISC Automatic Transmission Unit

56. REMOVE DIRECT CLUTCH PISTON





(a) Place SST on the No. 2 clutch balancer and compress the direct clutch return spring with a press.

SST : 09387-00020

(b) Using SST, remove the snap ring.

SST : 09350-30020

09350-07070

(c) Remove the No. 2 clutch balancer and direct clutch return spring sub-assembly from the direct clutch drum sub-assembly.





(d) Remove the O-ring from the No. 2 clutch balancer.

(e) Hold the direct clutch piston and apply compressed air to the oil hole of the direct clutch drum to remove the direct clutch piston.





Text in Illustration





(f) Remove the O-ring from the direct clutch piston.

(g) Remove the O-ring from the direct clutch drum sub- assembly.

57. INSPECT DIRECT CLUTCH RETURN SPRING SUB-ASSEMBLY Automatic Transmission Unit

58. REMOVE TRANSFER CASE ADAPTER REAR OIL SEAL





(a) Using a screwdriver, pry out the transfer case adapter rear oil seal.

Text in Illustration





NOTICE:
Do not damage the surface of the oil seal press fit hole.

HINT
Tape the screwdriver tip before use.

59. REMOVE OUTPUT SHAFT REAR RADIAL BALL BEARING

(a) Using snap ring pliers, remove the snap ring from the transmission case.

(b) Using SST, remove the output shaft rear radial ball bearing.

SST : 09308-00010





60. REMOVE NO. 2 BRAKE PISTON





(a) Set SST on the No. 2 brake piston return spring sub-assembly, tighten SST and compress the No. 2 brake piston return spring sub-assembly.

SST : 09380-50010

(b) Using SST, remove the snap ring and the No. 2 brake piston return spring.

SST : 09350-30020

09350-07070

(c) Hold the No. 2 brake piston and apply compressed air to the oil hole of the transmission case to remove the No. 2 brake piston.





Text in Illustration





(d) Remove the 3 O-rings from the No. 2 brake piston.

61. INSPECT NO. 2 BRAKE PISTON RETURN SPRING SUB-ASSEMBLY Automatic Transmission Unit