Disassembly
DISASSEMBLYCAUTION:
^ Thoroughly clean transmission exterior before overhauling it.
^ Keep working table, tools and hands clean while overhauling.
^ Use special care to handle aluminum parts so as not to damage them.
^ Do not expose removed parts to dust. Keep them clean always.
1. Remove torque converter.
2. Remove engine mounting LH bracket.
3. Remove oil level gauge and oil filler tube.
4. Drain transmission fluid. To drain fluid better, tilt transmission in various directions.
5. Remove oil pan and oil pan gasket.
NOTE:
^ For removal of oil pan, do not turn transmission over, as this will contaminate valve body with foreign matters in the bottom of oil pan.
^ When removing oil pan, tap around it lightly with a plastic hammer. Do not force it off by using a screwdriver or the like.
6. Disconnect couplers of direct clutch and 2nd brake solenoid valves.
7. Remove 2 oil tubes from lower valve body.
Remove them by pulling up tube end with a screwdriver.
8. Disconnect oil pressure control cable from throttle valve cam and then remove cable.
9. Remove oil strainer and lower valve body.
For removal of lower valve body, remove 11 bolts shown in figure.
CAUTION: Be careful not to let manual valve all off when removing valve body assembly.
10. Remove second brake accumulator upper spring and remove accumulator pistons and springs. Position a rag on pistons to catch each piston. To remove pistons, force low-pressure compressed air (1 kg/cm2, 15 psi, 100 kPa, max) into hole as shown, and pop each piston into the rag.
NOTE: Do not push accumulator pistons with fingers or anything before removing them. Pushing them may cause compressed fluid in accumulator to spew out of hole at face and clothes.
11. Remove second brake band cover and gasket.
12. After removing second brake band cover, check second brake piston stroke as follows.
a. Scribe mark on piston rod as shown in left figure.
b. Blow air into oil hole and measure rod stroke.
c. If stroke is out of specification, replace piston rod with the one of different length or replace second brake band. 2nd brake piston rod of 2 different lengths are available as spare parts.
Piston rod stroke "a": 1.5 - 3.0 mm (0.06 - 0.11 inch)
13. Remove second brake piston.
a. Install 17 mm socket with 8 mm bolt.
b. Apply valve lifter as illustrated and push in piston cover.
Special Tool
(A): 09916-14510
c. Remove snap ring by using screwdriver(s) or the like.
d. Remove tools and take out 2nd brake piston cover and piston. Tap cover head lightly to pull out cover.
14. Remove solenoid wire harness.
a. Remove wire hold plate securing nut.
b. Remove 2 wire clamps on transmission and pull out solenoid wire.
15. Remove oil pump.
a. Remove 6 oil pump securing bolts.
b. Remove oil pump by using special tool.
CAUTION: Make sure that 2nd brake piston and piston rod have been removed before oil pump removal. If not, they may cause breakage of 2nd brake band.
Special Tool
(B): 09918-48210
16. Remove transmission case housing.
a. Remove housing internal bolts and external bolts.
b. Remove housing while tapping around it lightly with a plastic hammer.
17. Remove second brake band pin.
18. Remove direct clutch and forward clutch at the same time while holding input shaft.
NOTE: Be careful not to loose ring gear race and bearing which may sometimes stick to input shaft.
19. Remove direct clutch assembly from input shaft.
20. Remove second brake band.
21. Remove front planetary ring gear and ring gear bearing.
22. Remove front planetary gear assembly.
23. Remove planetary sun gear and front planetary gear bearing.
24. Remove one way clutch snap ring by using a screwdriver.
NOTE: Use care not to damage transmission case when removing snap ring.
25. Remove one way clutch and rear planetary gear.
26. Remove rear planetary ring gear, ring gear bearing and washers.
27. Check 1st-reverse brake clearance. Measure clearance between snap ring and flange with feeler gauge. If out of specification, replace 1st-reverse brake discs or plates.
1st-reverse brake clearance 0.58 - 1.92 mm 10.023 - 0.075 inch)
28. Remove 2 snap rings by using a flat tip screwdriver.
29. Remove 1st-reverse brake flange, discs, plates and damper plate.
30. Remove differential gear assembly.
31. Remove rear cover.
a. Remove 10 bolts and 2 nuts.
b. Remove rear cover by tapping A with plastic hammer as shown in figure.
32. Remove reduction driven gear nut.
a. Undo caulking.
b. Shift manual shift lever to "P" so that output shaft is locked.
c. Loosen nut.
CAUTION: Calmly apply torque to loosen nut so as not to damage reduction gear or parking lock pawl.
33. Pull out reduction driven gear.
34. Drive countershaft out with a plastic hammer.
CAUTION: To avoid unnecessary damage of speed sensor due to contact with countershaft gear, it should be removed previously.
35. Remove output shaft by pushing outer race of internal output shaft bearing with special tools from inside of transmission case.
CAUTION:
^ Do not hit output shaft or shaft end will be damaged.
^ Hold special tools by hand while hitting them and avoid their bounce.
Special Tool
(C): 09925-18010
(D): 09927-08210
36. Remove parking lock pawl, pawl shaft and sleeve, etc.
a. Pull out parking lock pawl shaft and spring.
b. Remove parking lock pawl.
c. Pull out parking lock pawl sleeve.
d. Remove manual detent spring assembly and manual shift shaft.
37. Remove 1st-reverse brake piston.
a. Push down return spring assembly and remove snap ring.
b. Take out return spring assembly.
c. By blowing air, push out 1st-reverse brake piston.
CAUTION:
^ Blow air very carefully, or outer O-ring will be damaged.
^ Pull out piston by using long nose pliers, if failed to remove it by air blow.
^ Without replacing O-rings prepared, do not attempt to remove piston.