Part 1
COMPONENT PARTS REMOVALComponents
External Components:
Internal Components:
Transmission Disassembly
1. REMOVE TRANSMISSION CONTROL SHAFT LEVER
2. REMOVE [1][2]PARK/NEUTRAL POSITION SWITCH
a. Unstake the lock washer.
b. Remove the nut and bolt, and then remove the [1][2]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 ENGINE REAR MOUNTING
6. REMOVE DYNAMIC DAMPER
7. 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.
8. REMOVE VEHICLE SPEED SENSOR
a. Remove the vehicle speed sensor and stopper plate.
b. Remove the O-ring from sensor.
9. REMOVE TRANSFER CASE
Remove the 8 bolts and the case.
10. REMOVE SPEED SENSOR ROTOR AND KEY
a. Using a snap ring expander, remove the snap ring.
b. Remove the sensor rotor and key.
11. REMOVE TRANSMISSION HOUSING
a. Remove the 6 bolts.
b. Remove the transmission housing.
12. INSTALL TRANSMISSION CASE
Install the transmission case on the overhaul attachment.
13. 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 SST between the transmission case and oil pan, cut off applied sealer.
NOTICE: Be careful not to damage the oil pan flange.
c. Remove the pan by lifting the transmission case.
14. REMOVE OIL STRAINER AND GASKETS
Remove the 4 bolts and oil strainer case.
15. REMOVE OIL PIPE
Pry up the pipe ends with a large screwdriver and remove the pipe.
16. REMOVE SOLENOID WIRING
a. Disconnect the 3 connectors from the shift solenoid valve No.1, No.2 and SL.
b. Remove the stopper plate from the case.
c. Pull out the solenoid wiring from the transmission case.
d. Remove the O-ring from the grommet.
17. REMOVE VALVE BODY
a. Remove the 16 bolts.
b. Disconnect the throttle cable from the cam and remove the valve body.
18. REMOVE CHECK BALL BODY
Remove the check ball body and spring.
19. REMOVE ACCUMULATOR PISTONS AND SPRINGS
a. Applying compressed air to the oil hole, remove the Bo and Co 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 Co accumulator piston and spring.
e. Remove the O-ring from the piston.
20. REMOVE THROTTLE CABLE
a. Remove the retaining bolt and pull out the throttle cable.
b. Remove the O-ring from the cable.
21. 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.
22. 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 pinch
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.
23. .REMOVE OIL PUMP
a. Stand up the transmission.
b. Remove the 7 bolts holding the oil pump to the transmission case.
c. Using SST, remove the oil pump.
d. Remove the race from the oil pump.
e. Remove the O-ring from the oil pump.
24. REMOVE O/D PLANETARY GEAR WITH O/D DIRECT CLUTCH AND ONE-WAY CLUTCH
a. Remove the O/D planetary gear with the O/D direct clutch and one-way clutch from the transmission case.
b. Remove the race and assembled bearing and race.
c. Remove the bearing and race.
d. Remove the O/D planetary ring gear from the transmission case.
25. CHECK PISTON STROKE OF O/D BRAKE
a. Place SST and a dial indicator onto the O/D brake piston.
b. Measure the stroke while applying and releasing compressed air (392-785 kPa, 4-8kgf/cm', 57-114 psi).
Piston stroke: 1.75 - 2.05 mm (0.0689 - 0.0807 inch)
If the values are non-standard, inspect the disc.
26. REMOVE FLANGES, PLATES AND DISCS OF O/D BRAKE
a. Using a screwdriver, remove the snap ring.
b. Remove the flanges, plates and discs as a set.
27. CHECK PISTON ROD STROKE OF 2nd COAST BRAKE
a. Place a mark on the 2nd coast brake piston rod.
b. Using SST, measure the stroke while applying compressed air (392-785 kPa, 4-8 kgf/cm', 57-114 psi).
Piston stroke: 1.5 - 3.0 mm (0.059 - 0.118 inch)
If the values are non-standard, inspect the brake band.
28. REMOVE 2ND COAST BRAKE COVER, PISTON ASSEMBLY AND SPRING
a. Using SST, remove the snap ring.
b. Applying compressed air to the oil hole, remove the 2nd coast brake cover, piston assembly and spring.
c. Remove the 2 O-rings from the cover.