Valve Body Disassembly/Assembly

VALVE BODY ASSEMBLY





DISASSEMBLY





1. Remove detent spring, plate and manual valve.





2. Remove bolts from upper valve body side.





3. Remove bolts from lower valve body side





4. Separate upper valve body and lower valve body while pressing separator plate and valve body gasket against lower valve body to prevent balls, spring and others from coming out of valve body.





5. Confirm that there are valve, balls and plate as shown in figures.
- Front upper valve body assembly.





- Rear upper valve body assembly.





- Lower valve body assembly.

ASSEMBLY





1. Place separator plate and new lower valve body gasket on lower valve body assembly and tighten installation section of front upper valve body assembly with 2 bolts temporarily.





2. Place new upper valve body gasket on lower valve body assembly





3. While holding upper valve body gasket and lower valve body assembly together, install it on rear upper valve body assembly.





4. Tighten 3 bolts indicated in image temporarily.





5. Turn over lower valve body assembly and tighten 4 bolts indicated in image temporarily.





6. Remove 2 bolts tightened temporarily in Step 1.

NOTE: Be careful not to damage gasket.





7. Install lower valve body assembly on front upper valve body.





8. Tighten 3 bolts indicated in image temporarily.





9. Turn over control valve lower body and tighten 5 bolts indicated in image temporarily.





10. Tighten bolts on upper valve body side to specified torque.

Upper valve body bolt tightening torque: 5.5 Nm (0.55 kg-m, 4.0 ft. lbs.)

NOTE: Tighten bolts by a certain amount of torque evenly and repeat it several times till specified torque is attained.





11. Tighten bolts on lower valve body inside to specified torque.

Lower valve body bolt tightening torque: 5.5 Nm (0.55 kg-m, 4.0 ft. lbs.)

NOTE: Tighten bolts by a certain amount of torque evenly and repeat it several times till specified torque is attained.





12. After installing manual valve, install depent spring and plate and tighten detent spring bolt to specified torque.

Detent spring bolt tightening torque: 5.5 Nm (0.55 kg-m, 4.0 ft. lbs.)

FRONT UPPER VALVE BODY





DISASSEMBLY





1. Remove throttle valve keep plate.





2. Using screwdriver with vinyl tape or the like wound around its tip, hold cut back valve plug and remove cut back retainer with magnet. Then remove cut back plug, cut back valve and cut back valve spring.





3. Remove one cover bolt on front valve end cover and loosen the other to move cover as shown in figure. Remove secondary regulator valve sub assembly and secondary regulator valve spring. Then remove remaining loose cover bolt to remove front valve end cover.

WARNING: When moving cover, be sure to hold valve with finger to prevent secondary regulator valve sub assembly from jumping out.





4. Remove throttle cam bolt and then remove throttle valve cam, throttle cam return spring and cam spacer.





5. With throttle valve held as shown in figure, remove locating pin with magnet and then remove throttle valve and throttle valve primary spring.





6. Remove throttle valve and then remove secondary valve spring and throttle valve compensating ring(s).

NOTE: Write down how many throttle valve compensating rings there were, for throttle pressure varies with number of them.

ASSEMBLY





Assemble each component by reversing disassembly procedure and noting following points.





- Coil outer diameter and free length of each valve spring should be as listed below. Be sure to use each one of correct size.





- Install as many throttle valve compensating rings as written down when disassembled.
- Tighten throttle cam bolt to specified torque.

Throttle cam bolt tightening torque: 7.5 Nm (0.75 kg-m, 5.5 ft. lbs.)





- Tighten pressure relief valve bolts to specified torque.

Pressure relief valve bolt tightening torque: 5.5 Nm (0.55 kg-m, 4.0 ft. lbs.)

REAR UPPER VALVE BODY





DISASSEMBLY





1. Take out 6 valve body balls.





2. With 3-2 kickdown control valve plug pressed with finger, take out needle roller with magnet. Then remove 3-2 kickdown control valve plug, clutch sequence valve and reverse brake sequence valve spring.





3. With shift valve plug pressed with finger, take out shift valve retainer with magnet and then remove shift valve plug and 3-4 shift valve spring.





4. Remove 2 plate bolts. Then remove rear upper valve body plate and rear upper valve body gasket and take out 1-2 shift valve and shift valve spring.





5. With shift valve plug pressed with finger, remove valve retainer with magnet and then remove shift valve plug, 2-3 shift valve and shift valve spring.

ASSEMBLY





Assemble each component by reversing disassembly procedure and noting following points.





- Coil outer diameter and free length of each valve sprig should be as listed below. Be sure to use each one of correct size.





- Use new rear upper valve body gasket.
- Tighten plate bolt to specified torque.

Plate bolt tightening torque: 5.5 Nm (0.55 kg-m, 4.0 ft. lbs.)

LOWER VALVE BODY





DISASSEMBLY





1. Remove bypass valve, bypass valve spring, check ball valve damping spring, valve body ball and ball valve spring.





2. Remove lower valve body plate and lower valve body plate gasket.
3. Remove TCC (lock-up) control valve plate and TCC (lock-up) control valve gasket.





4. With pressure relief valve retainer pressed with finger, remove pressure relief valve bolt and then remove pressure relief valve retainer, pressure relief valve spring and pressure relief valve ball.





5. Remove TCC (lock-up) solenoid valve and Then remove O-ring from TCC solenoid valve.





6. After removing shift solenoid valve (A & B), remove solenoid valve gasket, low coast modulator valve spring, intercoast modulator valve spring and 2 intermediate coast modulator valves.





7. Pressing TCC (lock-up) control sleeve with finger and using magnet, remove locating pin and then remove TCC (lock-up) control sleeve, TCC (lock-up) control valve and TCC (lock-up) control valve spring.





8. Check which step of primary regulator valve sleeve (how many steps down from its tip) contacts primary regulator valve sleeve retainer.





9. Pressing primary regulator valve sleeve with finger and using magnet, remove primary regulator valve sleeve retainer and then remove primary regulator valve sleeve, primary regulator valve plunger, primary regulator valve spring and primary regulator valve.

ASSEMBLY





Assemble each component by reversing disassembly procedure and noting
following points.





- Coil outer diameter and free length of each valve spring should be as listed below. Be sure to use each one of correct size.





- Install primary regulator valve sleeve so that its tip is positioned as it was before disassembly.
- Use new TCC (lock-up) control valve gasket, solenoid gasket and lower valve body plate gasket.
- Tighten shift solenoid valve bolt to specified torque.

Shift solenoid valve bolt tightening torque: 10 Nm (1.0 kg-m, 7.5 ft. lbs.)





- Tighten TCC (lock-up) solenoid valve bolt to specified torque.

TCC solenoid valve bolt tightening torque: 5.5 Nm (0.55 kg-m, 4.0 ft. lbs.)

- Tighten pressure relief valve bolt to specified torque.

Pressure relief valve bolt tightening torque: 5.5 Nm (0.55 kg-m, 4.0 ft. lbs.)





- Tighten lower valve body plate, TCC (lock-up) control valve plate flange bolt to specified torque.

Plate bolt tightening torque: 5.5 Nm (0.55 kg-m, 4.0 ft. lbs.)