Disassembly

DISASSEMBLY





1. REMOVE TRANSMISSION CONTROL SHAFT LEVER LH
a. Remove the nut, washer and control shaft lever LH.





2. REMOVE PARK/NEUTRAL POSITION SWITCH ASSEMBLY
a. Using a screwdriver, pry out the lock washer.
b. Remove the nut, lock washer and bolt.
c. Remove the park/neutral position switch.
3. REMOVE OIL COOLER TUBE UNION
a. Remove the 2 oil cooler tube unions.
b. Remove the O-ring from the oil cooler tube union.





4. REMOVE TRANSMISSION REVOLUTION SENSOR
a. Remove the 2 bolts and 2 transmission revolution sensors.
b. Remove the O-ring from each sensor.





5. REMOVE AUTOMATIC TRANSAXLE BREATHER TUBE
a. Remove the 3 bolts.
b. Remove the breather tube.
c. Remove the O-ring from each tube.





6. REMOVE AUTOMATIC TRANSMISSION HOUSING
a. Remove the 10 bolts.
b. Remove the transmission housing.





7. REMOVE TRANSMISSION CASE ADAPTER SUBASSEMBLY
a. Remove the 8 bolts.
b. Remove the transmission case adapter assembly

HINT: Use a brass bar and a hammer to remove the extension housing assembly

c. Remove the gasket from the transmission case adapter adapter assembly.





8. REMOVE TRANSMISSION CASE ADAPTOR OIL SEAL
a. Using a screwdriver, pry out the oil seal.





9. FIX AUTOMATIC TRANSMISSION CASE SUBASSEMBLY
a. Install the transmission case on the overhaul attachment.
10. REMOVE AUTOMATIC TRANSMISSION OIL PAN SUB-ASSEMBLY

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

a. Remove the drain plug and the 20 bolts.
11. INSPECT AUTOMATIC TRANSMISSION OIL PAN SUB-ASSEMBLY





12. REMOVE VALVE BODY OIL STRAINER ASSEMBLY
a. Turn over the transmission.
b. Remove the 4 bolts holding the valve body oil strainer assembly to the valve body.
c. Remove the O-ring from the valve body oil strainer assembly.





13. REMOVE TRANSMISSION WIRE
a. Remove the ATF temperature sensor.
b. Remove the bolt and clamp.
c. Disconnect the 7 connectors from the shift solenoid valves.





d. Remove the bolt from the case.
e. Pull the transmission wire out of the transmission case.
f. Remove the O-ring from the transmission wire.





14. REMOVE TRANSMISSION VALVE BODY ASSEMBLY
a. Remove the 19 bolts.
b. Remove the valve body assembly.





15. REMOVE TRANSAXLE CASE GASKET
a. Remove the 3 transaxle case gaskets.





16. REMOVE BRAKE DRUM GASKET
a. Remove the 3 brake drum gaskets.





17. REMOVE CHECK BALL BODY
a. Remove the check ball body and spring.





18. REMOVE C-2 ACCUMULATOR PISTON
a. Applying compressed air to the oil hole, and remove the C-2 accumulator piston and spring.
b. Remove the 2 O-rings from the piston.

NOTICE: Be careful as the C-3 and B-3 accumulator piston may jump out.





19. REMOVE B-3 ACCUMULATOR PISTON
a. Applying compressed air to the oil hole, and remove the B-3 accumulator piston and spring.
b. Remove the 2 O-rings from the piston.

NOTICE: Be careful as the C-3 accumulator piston may jump out.





20. REMOVE C-3 ACCUMULATOR PISTON
a. Applying compressed air to the oil hole, and remove the C-3 accumulator piston and spring.
b. Remove the 2 O-rings from the piston.





21. REMOVE C-1 ACCUMULATOR VALVE
a. Remove the C-1 accumulator valve and 2 springs.





22. REMOVE PARKING LOCK PAWL BRACKET
a. Remove the 3 bolts and parking lock pawl bracket.





23. REMOVE PARKING LOCK ROD SUB-ASSEMBLY
a. Disconnect the parking lock rod from the manual valve lever.





24. REMOVE PARKING LOCK PAWL SHAFT
a. Pullout the parking lock pawl shaft from the front side, and then remove the lock pawl and spring.
b. Remove the E-ring from the shaft.





25. REMOVE MANUAL VALVE LEVER SUB-ASSEMBLY
a. Using a hammer and screwdriver, cut off the spacer and remove it from the shaft.





b. Using a pin punch and hammer, tap out the spring pin.

HINT: Slowly drive out the spring pin so that 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.





26. REMOVE MANUAL VALVE LEVER SHAFT OIL SEAL
a. Using a screwdriver, pry out the 2 oil seals.





27. REMOVE OIL PUMP ASSEMBLY
a. Remove the 10 bolts holding the oil pump from the transmission case.





b. Using SST, remove the oil pump.
SST 09350-30020 (09350-07020)





c. Remove the No. 1 thrust bearing race from the front oil pump.





28. REMOVE CLUTCH DRUM AND INPUT SHAFT ASSEMBLY
a. Remove the clutch drum and input shaft drum assembly from the transmission case.





b. Remove the clutch drum thrust washer and thrust needle roller bearing.
29. INSPECT NO. 2-WAY CLUTCH ASSEMBLY





30. REMOVE NO. 2-WAY CLUTCH ASSEMBLY
a. Remove the No. 2-way clutch assembly and No. 2 clutch drum thrust washer from the clutch drum and input shaft assembly





31. REMOVE NO. 3 BRAKE SNAP RING
a. Using a screwdriver, remove the No. 3 brake snap ring from the case.





32. REMOVE NO. 3 BRAKE DISC
a. Remove the flange, cushion plate, 4 discs and 4 plates from the case.
33. INSPECT NO. 3 BRAKE DISC





34. REMOVE 2ND BRAKE PISTON HOLE SNAP RING
a. Using SST, remove the snap ring.
SST 09350-30020 (09350-07060)





35. REMOVE 1-WAY CLUTCH ASSEMBLY
a. Remove the 1-way clutch assembly and No. 1 planetary carrier thrust washer from the case.





36. REMOVE 2ND BRAKE CYLINDER
a. Remove the 2nd brake cylinder from the case.





37. REMOVE 2ND BRAKE PISTON
a. Using SST, a press and screwdriver, remove the snap ring.
SST 09351-40010





b. Hold the 2nd brake piston and apply compressed air (392 kPa, 4.0 kgf/cm2, 57 psi) to the brake cylinder to remove the 2nd brake piston.





c. Remove the 2 O-rings from the 2nd brake piston.
38. INSPECT NO. 3 BRAKE PISTON RETURN SPRING SUB-ASSEMBLY
39. REMOVE FRONT PLANETARY GEAR ASSEMBLY
40. INSPECT FRONT PLANETARY GEAR ASSEMBLY
41. INSPECT 1-WAY CLUTCH ASSEMBLY





42. REMOVE FRONT PLANETARY RING GEAR
a. Remove the front planetary ring gear and bearing from the transmission case.





43. REMOVE CENTER PLANETARY RING GEAR
a. Using a screwdriver, remove the snap ring.





b. Remove the center planetary ring gear and front planetary ring gear flange from the front planetary ring gear.





44. REMOVE NO. 1 BRAKE DISC
a. Remove the flange, 3 discs and 3 plates from the case.
45. INSPECT NO. 1 BRAKE DISC





46. REMOVE BRAKE PISTON RETURN SPRING SNAP RING
a. Using a screwdriver, remove the brake piston return spring snap ring from the case.





47. REMOVE BRAKE PISTON RETURN SPRING SUB ASSEMBLY
a. Remove the brake piston return spring and No. 1 brake piston with the No. 1 brake cylinder from the transmission case.
48. INSPECT BRAKE PISTON RETURN SPRING SUB ASSEMBLY





49. REMOVE NO. 1 BRAKE PISTON
a. Hold the No. 1 brake piston and apply compressed air (392 kPa, 4 kgf/cm2, 57 psi) to the transmission case to remove the No. 1 brake piston.

HINT: If the piston does not pop out with compressed air, lift the piston out with needle-nose pliers.

b. Remove the 2 O-rings from the No. 1 brake piston.





50. REMOVE NO. 2 BRAKE DISC
a. Using a screwdriver, remove the snap ring from the case.





b. Remove the flange, brake piston return spring, 3 discs and 3 plates from the case.
51. INSPECT NO. 2 BRAKE DISC
52. INSPECT NO. 2 BRAKE PISTON RETURN SPRING SUB-ASSEMBLY





53. REMOVE NO. 2 BRAKE PISTON
a. Hold the No. 2 brake piston and apply compressed air (392 kPa, 4 kgf/cm2, 57 psi) to the transmission case to remove the No. 2 brake piston.

HINT: If the piston does not pop out with compressed air, lift the piston out with needle-nose pliers.

b. Remove the 2 O-rings from the No. 2 brake piston.





54. REMOVE CENTER PLANETARY GEAR ASSEMBLY
a. Remove the center planetary gear assembly, planetary sun gear and No. 4 thrust bearing race from the case.
55. INSPECT CENTER PLANETARY GEAR ASSEMBLY





56. REMOVE INTERMEDIATE SHAFT
a. Using a screwdriver, remove the snap ring from the case.





b. Remove the intermediate shaft with the No. 3-way clutch assembly from the case.
57. INSPECT NO. 3-WAY CLUTCH ASSEMBLY





58. REMOVE NO. 3-WAY CLUTCH ASSEMBLY
a. Remove the No. 3-way clutch assembly and 1 way clutch inner race from the intermediate shaft.





59. REMOVE REAR PLANETARY RING GEAR FLANGE SUB-ASSEMBLY
a. Remove the No. 8 thrust bearing race, thrust needle roller bearing, No. 7 thrust bearing race and planetary ring gear flange from the intermediate shaft.
60. INSPECT REAR PLANETARY RING GEAR FLANGE SUB-ASSEMBLY
61. INSPECT INTERMEDIATE SHAFT





62. REMOVE BRAKE PLATE STOPPER SPRING
a. Remove the brake plate stopper spring from the case.





63. REMOVE NO. 4 BRAKE DISC
a. Remove the 7 plates, 8 discs and 2 flanges from the case.
64. INSPECT NO. 4 BRAKE DISC





65. REMOVE REAR PLANETARY GEAR ASSEMBLY
a. Remove the rear planetary gear assembly from the case.





b. Remove the No. 9 thrust bearing race and thrust needle roller bearing from the rear planetary gear assembly.





c. Remove the thrust needle roller bearing from the case.
66. INSPECT REAR PLANETARY GEAR ASSEMBLY





67. REMOVE 1ST AND REVERSE BRAKE RETURN SPRING SUB-ASSEMBLY
a. Place SST on the spring retainer and compress the brake return spring.
SST 09350-30020 (09350-07050)
b. Using SST, remove the snap ring and brake return spring.
SST 09350-30020 (09350-07070)
68. INSPECT 1ST AND REVERSE BRAKE RETURN SPRING SUB-ASSEMBLY





69. REMOVE 1ST AND REVERSE BRAKE PISTON
a. Hold the No. 2 brake piston and apply compressed air (392 kPa, 4 kgf/cm2, 57 psi) to the transmission case to remove the No. 2 brake piston.

HINT: If the piston does not pop out with compressed air, lift the piston out with needle-nose pliers.

b. Remove the O-ring from the No. 2 brake piston.





70. REMOVE BRAKE REACTION SLEEVE
a. Using SST, remove the reaction sleeve.
SST 09350-30020 (09350-07080)
b. Remove the O-ring from the reaction sleeve.





71. REMOVE NO. 4 BRAKE PISTON
a. Using SST, remove the No. 4 brake piston.
SST 09350-30020 (09350-07090)
b. Remove the 2 O-rings from the No. 4 piston.