Disassembly

Automatic Transmission Unit Disassembly

Automatic Transmission Assembly Dismounting and Remounting

CAUTION:

If you air-blow a disassembled part near your face, fluid and dust blown away by the compressed air may injure your face, especially your eyes.

When air-blowing, always wear safety goggles and keep your face away from the part to be blown.

NOTE:

- Keep component parts in group for each subassembly and avoid mixing them up.
- Clean all parts thoroughly with cleaning solvent 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.
- Check that all oil passages are blown out and are not obstructed.
- Check mating surface for irregularities. If irregularities are found, remove them and clean mating surface again.
- Soak new clutch discs and brake discs in transmission fluid for at least 2 hours before assembly.
- Apply automatic transmission fluid to all O-rings.
- When installing seal ring, be careful so that it is not expanded excessively, extruded or caught.
- Before installation, be sure to apply automatic transmission fluid to sliding, rolling and thrusting surface of all component parts. Also after installation, be sure to check each part for proper operation.

1) Extract torque converter (1). And remove oil filler tube and dipstick.

NOTE:
Pulling the torque converter out of the transmission at an angle may damage the lip of the oil seal.

Pull the torque converter out of the transmission as straight as possible.









2) Remove input shaft speed sensor (1) and output shaft speed sensor (2).
3) Remove 6 adapter case fixing bolts and then remove adapter case (3) and gasket.

NOTE:
Remove adapter case straight so as not to cause damage oil seal lip.





4) Remove transmission range sensor (1).





5) Remove C-ring (1) and then remove speed sensor rotor (2).
6) Remove key.






7) Remove oil pump (1) by using special tools.
Special Tool

(A): 09913-65135

(B): 09927-66520

NOTE:
Remove oil pump straight so as not to cause damage shaft bushing surface.

8) Remove bearing at the rear of oil pump (1).
9) Remove O-ring from oil pump (1).
10) Holding input shaft (2) by hand, remove converter housing (3).





11) Check dimensions of overdrive (O/D) case (1) surface and clutch cylinder (2) surface for reassembly.
12) Remove overdrive (O/D) clutch assembly by holding input shaft (3).
13) Remove O/D case, bearing and bearing race.

NOTE:
Confirm direction of bearing and bearing race for reassembly.





14) Remove oil pan (1) and oil pan gasket.

Then remove magnets from oil pan and clean them to steel particles etc.

NOTE:
- Hold oil pan with oil pan side down to prevent foreign material in oil pan from entering valve body.
- If iron powder is found, there is possibility that bearing, gear or clutch plate is worn.





15) Remove oil strainer (1).





16) Remove overdrive (O/D) brake apply tube (1).
17) Disconnect connectors, and then remove solenoid wire harness (2).






18) Remove valve body (1) mounting bolts as shown in figure.





19) Remove accumulator pistons (1) by blowing air into holes (2) as shown in figure.

NOTE:
Hold accumulator piston (1) with nylon cloth while blowing air into holes.





20) Place transmission (1) upright as shown in figure.

NOTE:
- To prevent transmission case from getting damaged, protect its contacting surface with stand by using nylon cloth or the like.
- To facilitate work, use a stand with the size as shown in figure.









21) Check top surface level of forward clutch (2) against case (1) for reassembly.

22) Remove forward clutch.

NOTE:
Confirm direction of bearing and bearing race for reassembly.





23) Remove direct clutch (1).





24) Remove pawl bracket (1), and then parking lock rod (2) from manual shift lever.
25) Remove pawl spring (3), pawl pin and parking lock pawl (4).





26) Remove 2 bolts (1) from valve body side.






27) Remove center support assembly (1).





28) Remove retaining ring (1), planetary gear assembly leaf spring, bearing and bearing race.

NOTE:
- Be careful not to cause damage to case when removing retaining ring.
- Confirm direction of bearing and bearing race for reassembly.





29) Remove apply tube.
30) Remove reverse brake return spring (1) using special tools.
Special Tool

(A): 09941-84510

(B): 09926-98320









31) Remove reverse brake piston (1) by applying compressed air (400 - 800 kPa, 4 - 8 kgf/cm2, 57 - 113 psi) to oil hole (2).





32) Apply compressed air (400 - 800 kPa, 4 - 8 kgf/cm2, 57 - 113 psi) to oil hole (3) to remove brake reaction sleeve (1) and secondary reverse piston (2).
33) Remove brake reaction sleeve (1) and secondary reverse piston (2) by using special tools.
Special Tool

(A): 09920-20310





34) 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).






35) Remove oil seal (1) from both sides of transmission case.





36) Remove cover plate (1).