Transmission Disassembly
NOTE:
Thoroughly clean transmission exterior prior to disassembly. Use special care in handling aluminum components. DO NOT
turn transmission over when removing oil pan. Turning transmission will contaminate valve body with foreign matter from bottom of oil pan.
- Remove torque converter. Remove engine mounting LH bracket. Remove oil level gauge and oil filler tube. See Figure . Drain transmission fluid. Remove oil pan and gasket.
- Remove direct clutch and 2nd brake solenoid connectors. Using a screwdriver, pull up 2 oil tubes from lower valve body. Remove oil pressure control cable from throttle valve cam. Remove oil strainer. Remove 11 lower valve body bolts. Remove lower valve body. See Fig 1 and Figure . Ensure manual valve does not drop when removing valve body.
- Using 15 psi (1 kg/cm2 ) of compressed air in apply hole, pop out accumulator pistons into a shop towel. Remove pistons and springs. Remove 2nd brake band cover and gasket.
- Check 2nd brake piston stroke. Scribe mark on piston rod. Apply compressed air into oil hole. Measure 2nd brake piston rod stroke. See Fig 2 . Piston stroke should be .06-.12" (1.5-3.0 mm). If piston stroke exceeds specification, replace piston rod with longer rod. Piston rods are available in 2 sizes, 4.77" (121.3 mm) or 4.83" (122.7 mm). After installation of new rod, remeasure stroke. If stroke exceeds specification, replace 2nd brake band.
- Remove 2nd brake piston. Using 17-mm socket with 8-mm bolt and Valve Lifter (09916-14510), push in piston cover. Remove snap ring. Remove 2nd brake piston cover and piston.
- Remove solenoid wire hold plate nut. Remove 2 wire harness clamps on transmission. Remove solenoid wire. Remove 6 oil pump bolts. Using Remover (09918-48210), remove oil pump. Ensure 2nd brake piston and piston rod have been removed prior to oil pump removal to prevent damage of 2nd brake band.
- Remove transmission case housing while tapping lightly with a plastic hammer. Remove 2nd brake band pin. Remove direct and forward clutch together while holding input shaft. DO NOT lose ring gear race and bearing, which may sometimes stick to input shaft.
- Remove direct clutch from input shaft. Remove 2nd brake band. Remove front planetary ring gear and bearing. Remove front planetary gear. Remove planetary sun gear and front planetary gear bearing.
- Carefully remove one-way clutch snap ring. Remove one-way clutch and rear planetary gear. Remove rear planetary ring gear, ring gear bearing and washers.
- Check 1st and reverse brake clearance. Measure clearance between snap ring and flange. Clearance should be .023-.075" (.58-1.92 mm). See Fig 3 . If clearance exceeds specification, replace 1st and reverse brake discs and plates.
- Remove 1st and reverse brake flange, discs, plates and damper. Remove differential gear. Remove 10 bolts and 2 nuts. Remove rear cover by lightly tapping with a plastic hammer.
- Uncaulk reduction driven gear nut. Shift manual shift lever to "P". This locks output shaft. Carefully loosen nut so as not to damage reduction gear or parking lock pawl. Remove reduction gear.
- Ensure speed sensor has been removed. Drive out countershaft with a plastic hammer. Using Remover Handle (09925-18010) and Remover (09927-08210), remove output shaft by pushing outer race of internal output shaft bearing. To prevent damage, DO NOT hit output shaft or shaft end.
- Remove parking lock pawl shaft and spring. Remove parking lock pawl and sleeve. Remove detent spring and manual shift shaft. Push down return spring and remove snap ring. Remove return spring. Apply compressed air into case passage to remove 1st and reverse brake piston. If piston does not pop out with compressed air, use needle-nose pliers to remove.