Part 1 of 3
A: SECTIONS THAT CAN BE DETACHED/ASSEMBLED
B: DISASSEMBLY
1. External Parts
1. Place the transmission unit on a work bench, with the oil pan facing down.
CAUTION: Be careful not to bend or damage external parts.
2. Remove the drain plug, and drain differential oil. Tighten the plug temporarily after draining.
3. Remove the drain plug, and drain Automatic Transmission Fluid (ATF). Tighten the plug temporarily after draining.
4. Extract the torque converter clutch assembly.
NOTE:
- Extract the torque converter clutch horizontally. Be careful not to scratch the bushing inside the oil pump shaft.
- Note that oil pump shaft also comes out.
5. Remove the input shaft.
6. Remove the pitching stopper bracket.
7. Disconnect the air breather hose.
8. Remove the oil charger pipe, and remove the 0-ring from the flange face. Attach the O-ring to the pipe.
9. Remove the oil cooler inlet and outlet pipes.
CAUTION: When removing outlet pipes, be careful not to lose balls and springs used with retaining screws.
10. Remove harnesses from bracket.
2. Separation Of Each Section
1. Separation of torque converter clutch case and transmission case sections
CAUTION:
- Be careful not to damage the oil seal and bushing inside the torque converter clutch case by the oil pump cover.
- Be careful not to lose the rubber seal.
NOTE: Separate these cases while tapping lightly on the housing.
2. Separation of transmission case and extension sections
1. Remove vehicle speed sensor 1.
2. While pulling the extension slightly, disconnect the connector for the duty solenoid C (transfer).
CAUTION: Be careful not to cut the harness.
3. Separate both sections.
3. Transmission Case Section
1. Remove the reduction drive gear assembly.
2. Remove the reduction driven gear.
1. Straighten the staked portion, and remove the lock nut.
NOTE: Set the range selector lever to "P".
2. Using the ST, extract the reduction driven gear.
ST 899524100 PULLER SET
NOTE: Drill two holes in the puller.
3. Remove the parking pawl, return spring and shaft.
4. Loosen the taper roller bearing mounting bolts.
5. Place two wooden blocks on the workbench, and stand the transmission case with its rear end facing down.
CAUTION:
- Be careful not to scratch the rear mating surface of the transmission case.
- Note that the parking rod and drive pinion protrude from the mating surface.
6. Remove the oil pan.
NOTE: Tap the corners of the oil pan when removing.
7. Remove the oil cooler outlet pipe.
CAUTION: Be careful not to twist the pipe.
8. Disconnect the harness connectors for the solenoids and duty solenoids and the ground cord.
9. Remove the oil strainer.
CAUTION: Be careful not to damage O-ring on oil strainer.
10. Remove the control valve body and the two brackets.
11. Remove the three accumulator springs.
12. Loosen the reverse clutch drum lightly by turning the adjusting screw. Then remove the oil pump housing.
CAUTION: Be careful not to lose the total end play adjusting thrust washer.
13. Loosen the brake band adjusting screw and take out the strut.
14. Remove the brake band and reverse clutch.
NOTE: Contract the brake band with a clip.
15. Take out the high clutch.
CAUTION: Thrust needle bearing and bearing race are removed together with high clutch. Be careful not to lose them.
16. Take out the high clutch hub and the thrust bearing.
17. Take out the front sun gear and the thrust bearing.
18. Take out the front planetary carrier and the thrust bearing.
19. Take out the rear planetary carrier, rear sun gear and the thrust bearing.
20. Take out the rear internal gear and the thrust bearing.
21. Take out the one-way clutch outer race and the thrust washer.
22. Take out the overrunning clutch hub, the thrust washer and the thrust bearing.
23. Take out the forward clutch drum.
24. Take out the low & reverse brake section.
1. Remove the snap ring. Then remove the retaining plate, drive plates, driven plates, and dish plates as a unit.
2. Turning the case upside down, take out the one-way clutch inner race and spring retainer.
3. Take out the low & reverse piston by applying compressed air.
25. After removing the snap ring (inner), take out the servo piston by applying compressed air from the release pressure side.
CAUTION: Hold the servo piston with a rag so that it will not be ejected with the air pressure. In this case, do not allow your finger to be pinched between the pipe and retainer.
ST1 498677010 COMPRESSOR
ST2 399703600 PULLEY ASSEMBLY
26. Apply compressed air from the operating pressure side, and take out accumulator (3-4), accumulator (1-2), accumulator (2-3), accumulator and spring (N-D).
27. Remove the range select lever.
28. Remove the detention spring.
29. Remove the parking rod together with the manual lever. Then remove the manual shaft by pulling off the straight pin.
CAUTION: Be careful not to damage the lips of the pressfitted oil seal in the case.
30. Remove the inhibitor switch.
31. Remove the transmission harness.
CAUTION: Be careful not to damage the cord insulation.
4. Torque Converter Clutch Case Section
1. Wrap the axle shaft serration with vinyl tape.
2. Remove the differential side retainer with ST.
ST 499787000 WRENCH ASSEMBLY
CAUTION: Hold the differential case assembly by hand to avoid damaging retainer mounting hole of the torque converter clutch case and speedometer gears.
3. Extract the axle shaft with ST1 and ST2.
ST1 499095500 REMOVER
ST2 499247300 INSTALLER
CAUTION: Do not reuse the circlip.
4. Remove the differential case assembly.
CAUTION:
- Be careful not to damage the retainer mounting hole of the torque converter clutch case and the speedometer gears.
- Remove the seal pipe if it is attached. (Reusing is not allowed.)
5. Remove the snap ring. Then remove the speedometer driven gear.
6. Tap out the speedometer shaft to the outside of the case, and remove the oil seal.
5. Extension Section
1. Take out the transfer clutch by lightly tapping the end of the rear drive shaft.
CAUTION: Be careful not to damage the oil seal in the extension.
2. Remove duty solenoid C, transfer valve body and the transfer pipe.
CAUTION:
- Take out the inlet filter.
- Do not damage the O-ring.
- Be careful not to bend the pipe.
3. Take out the roller bearing inner race with ST.
ST 398527700 PULLER
4. Take out the roller bearing outer race with ST.
NOTE: Hook ST in the inner side of the roller bearing outer race.
ST 398527700 PULLER
C: ASSEMBLY OF OVERALL TRANSMISSION
1. Torque Converter Clutch Case Section
1. Check the appearance of each component and clean.
CAUTION: Make sure each part is free of harmful cuts, damage and other faults.
2. Install the washer and snap ring to the speedometer shaft with ST, and set the oil seal. Then force-fit the shaft to the torque converter clutch case.
ST 499827000 PRESS
3. Install the speedometer driven gear to the speedometer shaft, and secure with a snap ring.
4. Force-fit the oil seal to the torque converter clutch case with ST.
ST 398437700 DRIFT
5. Install the differential assembly to the case, paying special attention not to damage the speedometer gears (drive and driven) and the inside of the case (particularly, the differential side retainer contact surface).
6. Install the circlip to the axle shaft, insert the shaft into the differential assembly, and tap it into position with a plastic hammer.
Thrust play.
Approximately 0.3 - 0.5 mm (0.012 - 0.020 inch)
CAUTION:
- If no play is felt, check whether the shaft is fully inserted. If shaft insertion is correct, replace the axle shaft.
- Be sure to use a new circlip.
7. Wrap vinyl tape around the splined portion of the axle shaft.
8. Install the oil seal and outer race (taper roller bearing) to the differential side retainer. Then screw in the retainer and the O-ring after coating the threads with oil.
CAUTION:
- Pay attention not to damage the oil seal lips.
- Do not confuse the RH and LH oil seals.
- Keep the O-ring removed from the retainer.
9. Using the ST, screw in the retainer until light contact is felt.
ST 499787000 WRENCH ASSEMBLY
NOTE: Screw in the RH side slightly deeper than the LH side.