Unit Disassembly
Disassembly
1. Extract torque converter (1).
CAUTION: Remove torque converter as much straight as possible. Leaning it may cause to damage oil seal lip.
2. Measure starting torque of differential gear assembly using special tool.
Special tool (A): 09928-06050
Specified value (a): 1.0 - 1.4 Nm (0.1 - 0.14 kgf-m, 0.72 - 1.0 ft. lbs.)
NOTE: Record actual starting torque of differential assembly for installation reference.
3. Remove oil cooler pipes (1).
NOTE: Never reuse gaskets (2) after removal.
4. Pull out transmission range sensor (1).
a. Remove manual shift lever (2).
b. Pry off lock washer (4).
c. Remove lock nut (3).
d. Remove lock washer and rubber plate.
e. Remove two bolts (5).
NOTE: Never reuse lock washer after removal.
5. Remove oil level gauge (1), oil filler tube (2), output shaft speed sensor (3) (for A/T), input shaft speed sensor (4) and vehicle speed sensor (5) (for speedometer).
6. Remove transmission housing by removing 15 bolts as shown.
NOTE: Never reuse removed two bolts (1).
7. Pull out differential gear assembly.
8. Clean and wipe off gasket sealer on mating surface between transmission housing and transmission case.
9. Remove three gaskets at transmission case side.
NOTE: Never reuse removed gaskets.
10. Remove six bolts of oil pump body (1), then remove oil pump body by hand.
NOTE:
^ Use care not to cause damage to shaft bushing surface.
^ If oil pump body can't be removed by hand, remove it by using gear puller as shown in the figure.
11. Remove oil reserve plate (1) by removing two bolts.
12. Remove oil strainer (2).
13. Remove manual detent spring (1) by removing two bolts.
14. Remove transmission side cover (1) by removing 12 bolts.
NOTE: Never reuse removed two bolts (A).
15. Release solenoid wiring harness from clamp.
16. Disconnect throttle pressure control solenoid (1), No.1 shift solenoid (2), No.2 shift solenoid (3) and TCC control solenoid (4) couplers.
17. Remove valve body assembly (5) by removing eight bolts.
NOTE: Each bolt length is indicated in the figure.
CAUTION: Be careful not to let manual valve fall off when removing valve body assembly.
18. Remove solenoid coupler mounting bolt and remove solenoid coupler and its harness. Then remove transmission fluid temp. sensor (9) and its harness from clamps.
19. Remove two gaskets (1).
NOTE: Never reuse removed gaskets.
20. Remove snap ring (1) using special tool.
Special tool (A): 09900-06108
21. Pull out 2nd and 4th brake cover with O-ring by using pliers or the like.
22. Inspect 2nd and 4th brake piston rod stroke.
a. Set dial gauge and magnetic stand (special tools).
Special tool
(B): 09900-20606
(C): 09900-20701
b. Plug oil hole (1).
c. Measure piston rod stroke while applying and releasing compressed air (400 - 800 kPa, 4 - 8 kgf/cm2, 57 - 113 psi) from oil hole (2).
Specified piston rod stroke 1.98 - 2.42 mm (0.078 - 0.095 inch)
NOTE: If piston rod stroke exceeds above specification, adjust piston rod or inspect band assembly of 2nd and 4th brake for damage, wear or discoloration.
23. Pull out reverse clutch assembly (1).
24. Remove 2nd and 4th brake band assembly (2).
25. Remove straight pin (3).
Reference value of straight pin
Length: 45 mm (1.77 inch)
Outside diameter: 8 mm (0.31 inch)
26. Apply valve lifter as illustrated and push in brake inner cover.
Special tool
(A): 09916-14510
(B): 09916-48210
27. Remove snap ring by using snap ring pliers (special tool).
Special tool (C): 09900-06108
28. Remove tools and take out 2nd and 4th brake piston assembly (2) and brake inner cover.
NOTE: If 2nd and 4th brake piston assembly doesn't come out, apply compressed air through oil hole.
29. Remove spring (3).
30. Disassemble 2nd and 4th brake piston assembly.
a. Remove brake inner cover (1) and O-rings (2).
NOTE: Never reuse removed O-ring.
b. Remove E-ring (1), brake piston (2), spring (3) and rod washer (4).
31. Loosen six bolts of transmission rear cover.
32. Lightly and uniformly tap two rib sections of transmission rear cover, using plastic hammer.
33. Remove ten bolts and engine mounting LH bracket.
NOTE: Never reuse two bolts (A) after removal.
34. Pull out transmission rear cover (1) with forward clutch subassembly installed.
35. Remove five gaskets (1).
NOTE: Never reuse removed gaskets.
36. Remove planetary carrier (2) for front/rear planetary ring gear (3) and sun gear assembly (1) with the following integral bearing installed.
Integral bearing with race dimension
Outside diameter: 32.3 mm (1.27 inch)
Inside diameter: 19.0 mm (0.75 inch)
Race thickness: 2.7 mm (0.11 inch)
37. Pull out sun gear assembly.
38. Inspect 1st and reverse brake piston stroke.
a. Set special tool (dial gauge and magnetic stand).
Special tool
(A): 09900-20606
(B): 09900-20701
b. Measure piston stroke while applying and releasing compressed air (400 - 800 kPa, 4 - 8 kgf/cm2, 57 - 113 psi) from oil hole (1).
Piston stroke specified value: 1.4 - 2.2 mm (0.055 - 0.087 inch)
NOTE: If piston stroke exceeds specification above, inspect or replace flanges and discs.
39. Remove snap ring (1) using flat screwdriver.
40. Remove flange brakes "P" disc, clutch and flanges "D" and plate brakes "P" in the following order.
F-->D-->P-->D-->P-->D-->P-->D-->F
41. Remove retainer ring (1) and brake piston return spring (2).
42. Remove 1st and reverse brake piston with O-ring installed while applying and releasing compressed air (400 - 800 kPa, 4 - 8 kgf/cm2, 57 - 113 psi) through oil hole section (A).
NOTE:
^ Never reuse removed O-rings.
^ If piston will not pop out, it is recommended to use needle nose pliers for removal.
43. Remove parking lock pawl (1), pawl bracket (2) and spring by removing two bolts.
44. Pry off torsion spring (3) of parking lock pawl.
45. Remove parking lock pawl by pulling out pawl shaft (4) with torsion spring installed.
46. Pullout counter driven gear assembly (5) towards you.
47. Remove integrated needle roller bearing (1) with race.
Race dimension
Outside diameter: 65.7 mm (2.59 inch)
Inside diameter: 51.0 mm (2.01 inch)
Thickness: 2.8 mm (0.11 inch)
48. Remove transmission lubrication tube (2).
49. Measure starting torque of counter drive gear subassembly using torque wrench and special tool.
Special tool (A): 09927-26010
Specified value of counter drive gear subassembly starting torque (a): 0.05 - 0.25 Nm (0.005 - 0.025 kgf-m, 0.037 - 0.180 ft. lbs.)
50. Clamp special tool in a vice (1) and place transmission housing onto special tool above.
Special tool (B): 09927-76040
51. Measure transmission housing rotational torque using push-pull gauge or the like.
Specified value of transmission housing rotational torque 0.05 - 0.15 Nm (0.005 - 0.015 kgf-m, 0.037 - 0.108 ft. lbs.)
52. Remove snap ring.
53. Press counter drive gear subassembly (1) using special tool.
Special tool (C): 09925-86010
54. Remove slotted spring pin (3) using pin punch or the like.
NOTE: Never reuse removed spacer (2) and slotted spring pin.
55. Remove manual valve lever shaft subassembly (1), manual valve lever (4) and oil seal.
NOTE: Never reuse removed oil seal.