Part 1

TRANSMISSION DISASSEMBLY

External Components:

Internal Components:

1. Remove transmission control shaft lever.





2. Remove park/neutral position switch.
a. Unstake the lock washer.
b. Remove the nut and bolt, and then remove the park/neutral position switch.
c. Remove the lock washer and grommet.





3. Remove ATF temperature sensor.
a. Remove the temperature sensor.
b. Remove the O-ring from the sensor.





4. Remove transmission side union and elbow.
a. Remove the union and elbow.
b. Remove the O-rings from the union and elbow.





5. Remove breather hose.
Disconnect the breather hose from transfer upper cover and transmission control retainer.





6. Remove engine rear mounting.





7. Remove dynamic damper.





8. Remove propeller shaft upper dust cover and transfer from transmission.
a. Remove the dust cover bolt from the bracket.
b. Remove the transfer adaptor rear mounting bolts.





c. Pull the transfer straight up and remove it from the transmission.





9. Remove vehicle speed sensor.
a. Remove the vehicle speed sensor and stopper plate.
b. Remove the O-ring from sensor.





10. Remove transfer case.
Remove the 7 bolts and the case.





11. Remove speed sensor rotor and key.
a. Using a snap ring expander, remove the snap ring.
b. Remove sensor rotor and key.





12. Remove transmission housing.
a. Remove the 6 bolts.
b. Remove the transmission housing.





13. Install transmission case.
Install the transmission case on the overhaul attachment.





14. Remove oil pan.

NOTICE: Do not turn the transmission over as this will contaminate the valve body with any foreign matter at the bottom on the pan.

a. Remove the 19 bolts.





b. Install the blade of Special Service Tool (SST) 09032 - 00100 or equivalent, between the transmission case and oil pan, cut off applied seeder.

NOTICE: Be careful not to damage the oil pan flange.

c. Remove the pan by lifting the transmission case.





15. Remove oil strainer and gaskets.
a. Remove the 11 bolts holding the oil strainer to the oil strainer case.
b. Remove the oil strainer and gasket.
c. Remove the 5 bolts and oil strainer case.
d. Remove the 2 gaskets from the case.





16. Remove oil pipe.
Pry up pipe ends with a large screwdriver and remove the pipe.





17. Remove solenoid wiring.
a. Disconnect the 3 connectors from No.1, No.2 and SL solenoids.





b. Remove the stopper plate from the case.
c. Pull out the solenoid wiring form the transmission case.
d. Remove the O-ring from the grommet.





18. Remove valve body.
a. Remove the 16 bolts.





b. Disconnect the throttle cable from the cam and remove the valve body.





19. Remove check ball body.
Remove the check ball body and spring.





20. Remove accumulator pistons and springs.
a. Applying compressed air to the oil hole, remove the B0 and C0 accumulator pistons and 3 springs.
b. Remove the O-ring from each piston.





c. Applying compressed air to the oil hole, remove the BO accumulator piston and spring.





d. Applying compressed air to the oil hole, remove the C0 accumulator piston and spring.
e. Remove the O-ring from the piston.





21. Remove throttle cable.
a. Remove the retaining bolt and pull out the throttle cable.
b. Remove the O-ring from the cable.





22. Remove parking lock rod and pawl.
a. Remove the parking lock pawl bracket.





b. Disconnect the parking lock rod from the manual valve lever.





c. Remove the E-ring from the shaft.
d. Pull the parking lock pawl shaft out from the front side, then remove the pawl and spring.





23. Remove manual valve lever shaft.
a. Using a screwdriver and hammer, cut off the spacer and remove it from the shaft.





b. Using a pin punch, drive out the spring pin.

HINT: Slowly drive out the spring pin so it does not fall into the transmission case.

c. Pull the manual valve lever shaft out through the case and remove the manual valve lever.





d. Using a screwdriver, remove the 2 oil seals.