Part 1
Automatic Transmission Unit DisassemblyReference: Automatic Transmission Assembly (with Transfer) Dismounting and Remounting
CAUTION:
^ Keep component parts in group for each subassembly and avoid mixing them up.
^ Clean all parts with cleaning solvent thoroughly and air dry them.
^ Use kerosene or automatic transmission fluid as cleaning solvent.
^ Do not use wiping cloths or rags to clean or dry parts.
^ All oil passages should be blown out and checked to make sure that they are not obstructed.
^ Keep face and eyes away from solvent spray while air blowing parts.
^ Check mating surface for irregularities and remove them, if any, and clean it again.
^ Soak new clutch discs and brake discs in transmission fluid for at least 2 hours before assembly.
^ Replace all gaskets and O-rings with new ones.
^ Apply automatic transmission fluid to all O-rings.
^ When installing seal ring, be careful so that it is not expanded excessively, extruded or caught.
^ Replace oil seals that are removed and apply grease to their lips.
^ Before installing, be sure to apply automatic transmission fluid to sliding, rolling and thrusting surface of all component parts. Also after installation, make sure to check each part for proper operation.
^ Always use torque wrench when tightening bolts.
1. Extract torque converter (1) from transmission.
CAUTION:
Remove torque converter as much straight as possible.
Leaning it may cause to damage oil seal lip.
2. Remove breather pipe (1) from transmission.
3. Remove output shaft speed sensor (1) and input shaft speed sensor (2).
4. Remove the nut, the washer and manual select lever (1).
5. Unbend bend parts of lock washer (1) and then remove manual shift shaft nut (2), lock washer and grommet.
6. Remove transmission range sensor (3) by removing sensor bolt.
7. Remove oil cooler pipes (1) from transmission.
8. Remove converter housing (1) by removing 10 bolts.
9. For 2WD model, perform following procedure.
a. Remove extension housing (1) by removing 6 bolts.
b. Remove snap ring (1) from output shaft.
c. Remove thrust needle roller bearing (1) and then remove bearing races (2).
d. Remove extension housing dust deflector (1) using brass bar and hammer.
e. Remove oil seal (1) from extension housing by using special tool.
Special Tool
(A): 09913-50121
10. For 4WD model, perform following procedure.
a. Remove transmission case adapter (1) by removing 8 bolts.
b. Remove transmission case adaptor oil seal (1) by using flat end rod or the like.
11. Remove oil pan bolts (1).
12. Remove oil pan and oil pan gasket from transmission case.
13. Remove the 4 magnets (1) and clean them to steel particles etc.
14. Remove oil strainer (1) from valve body assembly.
15. Remove transmission fluid temperature sensors (1) from sensor clamps (2).
16. Remove wire harness clamp (3).
17. Disconnect the following connectors from shift solenoid-A, shift solenoid-B, shift solenoid-E, TCC solenoid, pressure control solenoid-A, pressure control solenoid-B and pressure control solenoid-C.
18. After removing bolt (1) pull out transmission wire connector (2) from transmission case.
CAUTION: When pulling transmission wire harness out of transmission case, take care not to damage connectors and transmission fluid temperature sensors at narrow exist of case.
19. Remove spring plate (1) and manual shift lever spring (2).
20. Remove valve body assembly (3) by removing 19 bolts.
21. Remove check ball body (1) and spring (2).
22. Remove transmission case gaskets (1).
23. Remove brake drum gaskets (1) from transmission case.
24. Remove direct clutch accumulator piston (1) by compressed air (392 kPa, 4.0 kg/cm2, 57 psi) into hole (2).
NOTE: Cover accumulator piston (1) with shop cloth while blowing because A/T fluid should be spattered.
25. Remove direct clutch accumulator piston spring from transmission case.
26. Remove 2nd (No.3) brake accumulator piston (1) by compressed air (392 kPa, 4.0 kg/cm2, 57 psi) into hole (2).
NOTE: Cover accumulator piston (1) with shop cloth while blowing because A/T fluid should be spattered.
27. Remove 2nd (No.3) brake accumulator piston spring from transmission case.
28. Remove reverse clutch accumulator piston (1) by compressed air (392 kPa, 4.0 kg/cm2, 57 psi) into hole (2).
NOTE: Cover accumulator piston (1) with shop cloth while blowing because A/T fluid should be spattered.
29. Remove reverse clutch accumulator piston springs from transmission case.
30. Remove forward clutch accumulator piston (1).
31. Remove forward clutch accumulator piston springs from transmission case.
32. Remove parking pawl bracket (1).
33. Remove parking lock rod (2) from manual shift lever (1).
34. Pull out parking pawl pin (1) to oil pump side and then remove parking lock pawl (2) and parking pawl spring (3).
35. Remove manual shift shaft and lever as follows.
a. Undo caulking of sleeve cover (1) by using flat end rod or the like and hammer.
b. Drive out manual shift lever pin (1) by using special tool and hammer.
Special Tool
(A): 09922-89810
c. Pull out manual shift shaft (2) from transmission case, and then remove manual shift lever (3) and sleeve cover (4).
