AUTOMATIC TRANSMISSION DISASSEMBLY

id051300260100


Precaution

The following are precautions that must be followed performing removal/installation.

1.  Handle electronic parts with care

•  Do not pull the wiring harness forcibly when disconnecting the connector. Unlock the first and pull the connector.
•  When connecting the connector, verify that it is inserted until it is properly locked. (Verify that a click sound is heard.)
•  Do not apply shock to electronic parts. Replace with new parts if they have been dropped or subjected to shock.

2.  Prevent foreign matter from penetrating

•  Be sure to remove foreign matter such as dust and sand from the automatic transaxle before removing parts.
•  Protect removed parts from dust with an object such as a vinyl sheet.
•  Do not use cotton work gloves or shop rags as frayed strings might get caught in the unit. Work with bare hands or use vinyl gloves.

3.  Prevent scratching

•  Do not pry with a screwdriver forcibly. Slightly tap the case with a plastic hammer when separating component cases at seams.
•  Do not pull the valve forcibly.
•  Be careful not to get the wiring harness caught between parts during installation.

4.  Prevent incorrect or insufficient, installation or missing parts

•  Be careful not to install parts incorrectly or lose parts since there are similar types of O-rings, snap rings, bearings and races. Be careful to for straighten parts and check their installation direction.
•  Be careful not to drop small parts such as check balls or lose them during installation.

5.  Wash parts and apply oil

•  Wash each part before installing and dry using compressed air, and then apply the specified ATF type JWS3309.
•  Soak discs in ATF type JWS3309 before installing. In particular, soak a new disc for 2 h or more so that the oil seeps into the lining.
•  If the thrust bearing or race falls during installation, use a small amount of yellow petrolatum grease.
•  Apply ATF type JWS3309 to contact and rotating surfaces.
•  Do not apply oil or drive the vehicle immediately after installing a part applied with sealant. Leave it for one hour or more.
•  Do not wash aluminum parts or rubber parts with alkaline chemicals.
•  Do not wash rubber parts with isopropyl alcohol (IPA).

6.  ATF care

•  If ATF is spilled on the floor, wipe it off immediately, as it is quite slippery and dangerous.
•  Be sure to use JWS3309 type ATF.


Disassembly


Components

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1
Extension dust deflector
2
Extension housing shroud
3
Oil seal
4
Under cover (with i-stop)
5
Coupler bracket (with i-stop)
6
Hose (with i-stop)
7
Electric AT oil pump (with i-stop)
8
Spacer (with i-stop)
9
Gasket (with i-stop)
10
Elbow (with i-stop)
11
O-ring (with i-stop)
12
Extension housing
13
Oil seal (with i-stop)
14
Snap ring (MX-5 (ND))
15
Bearing (MX-5 (ND))
16
Filler plug
17
O-ring
18
Check plug
19
O-ring
20
VSS
21
Breather hose
22
Breather tube
23
Oil pipe (MX-5 (ND))
24
Bracket (MX-5 (ND))
25
Turbine sensor
26
TR switch
27
Torque converter
28
Converter housing
29
Breather pipe

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1
Drain plug
2
Gasket
3
Overflow plug
4
Gasket
5
Oil pan
6
Oil pan gasket
7
Magnet
8
Oil strainer
9
O-ring
10
Detent spring cover
11
Detent spring
12
Control valve body
13
Oil seal
14
Manual shaft
15
Manual shaft washer
16
Pin
17
Oil seal
18
Manual valve
19
Check valve
20
Spring
21
Accumulator piston
22
Spring
23
Bracket
24
Parking rod
25
Driven plate
26
Shaft parking pawl
27
Spring
28
Parking pawl
29
Snap ring
30
Spring
31
O-ring
32
Accumulator piston
33
Accumulator spring
34
Gasket
35
Gasket
36
O-ring
37
Clip
38
Coupler component
39
Oil strainer (electric AT oil pump) (with i-stop)
40
O-ring (with i-stop)

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1
Oil pump
2
O-ring
3
Bearing race
4
Thrust needle bearing
5
Bearing race
6
Thrust needle bearing
7
Clutch drum component
8
Thrust washer
9
F2 one-way clutch
10
Thrust washer
11
Snap ring
12
Driven plate
13
Drive plate
14
Snap ring
15
B3 brake piston component
16
F1 one-way clutch
17
Thrust washer
18
Bearing race
19
Front planetary gear component
20
Thrust washer
21
Bearing race
22
Thrust needle bearing
23
Front and middle ring gear component
24
Thrust needle bearing
25
Bearing race
26
Front planetary gear component
27
Sun gear

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1
Retaining plate
2
Driven plate component
3
Driven plate
4
Snap ring
5
Pinion return spring
6
B1 brake piston component
7
Snap ring
8
Retaining plate
9
Drive plate
10
Driven plate
11
Driven plate
12
Piston return spring
13
B2 brake piston component
14
Snap ring
15
Inner race
16
F3 one-way clutch
17
Rear ring gear component
18
Bearing race
19
Needle bearing
20
Bearing race
21
Intermediate shaft

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1
Snap ring
2
Bearing race
3
Thrust needle bearing
4
Bearing race
5
Stopper spring
6
O-ring
7
O-ring
8
Inner brake piston
9
O-ring
10
O-ring
11
Sleeve
12
O-ring
13
B4 brake piston
14
Piston return spring
15
Snap ring
16
Brake tube
17
Thrust needle bearing
18
Bearing race
19
Rear planetary gear component
20
O-ring
21
Inner brake piston
22
O-ring
23
O-ring


Disassembly procedure

1.  Remove the drain plug and gasket.

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Caution
•   Do not damage the oil seal.
•   Do not drop the torque converter.

2.  Remove the torque converter.

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3.  Remove the breather hose, breather tube and breather pipe.

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4.  Remove the oil pipe and bracket. (MX-5 (ND))

LH

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RH

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Caution
•  Do not damage the turbine sensor.

5.  Remove the turbine sensor.

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Caution
•   Do not damage the VSS.

6.  Remove the VSS.

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7.  Lift up the lock washer using a flathead screwdriver.

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8.  Remove the nut and lock washer.

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Caution
•   Do not damage the TR switch.

9.  Remove the TR switch.

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10.  Remove the bolts as shown in the figure.

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Caution
•  Do not damage the fitting surface of the transmission case and the converter housing.

11.  Using a plastic hammer, tap the converter housing to remove it.

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Caution
•  Do not damage the fitting surface of the extension housing and the extension dust deflector.

12.  Using a plastic hammer and slab of wood, tap the extension dust deflector to remove it.

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Caution
•   Do not damage the extension housing.

13.  Using a flathead screwdriver, remove the extension housing shroud.

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Caution
•  Do not damage the extension housing.

14.  Using a flathead screwdriver, remove the oil seal.

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15.  Remove the electric AT oil pump. (with i-stop)

(1)  Disconnect the connector and wiring harness clip.
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(2)  Remove the under cover.
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Caution
•  Be careful not to deform the under cover and coupler bracket, if they are deformed the electric AT oil pump may malfunction.
(3)  Remove the coupler bracket.
(4)  Slide the hose clamps upward and remove the hose.
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Caution
•  Because the ATF remaining in the hose may leak, drain the ATF into a container to prevent if from getting on parts.
(5)  Remove the electric AT oil pump.
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Caution
•  Do not use an impact wrench, otherwise damage in the electric oil pump might occur.
•  Be careful not to drop the electric AT oil pump. When removing the bolts, support the electric AT oil pump by hand to prevent it from falling.
(6)  Remove the spacer and gasket.
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Caution
•  Do not use an impact wrench, otherwise damage in the electric oil pump might occur.
•  Be careful not to drop the spacer. When removing the bolts, support the spacer by hand to prevent it from falling.
Note
•  Remove the spacer and gasket only if they need to be replaced.
•  If the spacer is not removed, completely remove any ATF leaked onto and around the spacer to prevent false ATF leakage detection.
(7)  Remove the elbow and O-rings from the spacer.
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Caution
•  Be careful not to scratch or damage the elbow pipe coating, otherwise it could cause a malfunction.

16.  Remove the bolts as shown in the figure.

MX-5 (ND)

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MX-5 (NC), RX-8 (SE)

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Caution
•  Do not damage the fitting surface of the transmission case and the extension housing.

17.  Using a plastic hammer, tap the extension housing to remove it.

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18.  Remove the snap ring, bearing, and oil seal. (MX-5 (ND))

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19.  Remove the snap ring using snap ring pliers.

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Caution
•  Do not damage the fitting surface of the transmission case and the oil pan.
•  Do not deform the oil pan.

20.  Remove the bolt as shown in the figure and remove the oil pan and gasket.

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21.  Remove the oil strainer (electric AT oil pump) and O-ring. (with i-stop)

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22.  Remove the magnet from the oil pan.

Note
•  Inspect the oil pan for foreign material and determine the worn areas of the transmission. For ferrous metal related areas, check for wear of the bearings, gears, and plates. For brass related metal (non-magnetized), check for bushing wear.
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23.  Remove the oil strainer from the control valve body component.

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24.  Remove the O-ring from the oil strainer.

25.  Disconnect the solenoid connectors from the solenoids.

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26.  Disconnect the coupler component from the clamps.

27.  Remove the lock plate from the control valve body component.

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Caution
•  When installing the control valve body, make sure that it does not interfere with the coupler component.

28.  Disconnect the transmission fluid temperature switch from the control valve body component.

29.   Fix the coupler component with tape to the transmission case as shown in the figure.

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30.  Disconnect the detent spring cover and detent spring from the control valve body component.

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Caution
•  Do not drop the control valve body component.

31.  Remove the bolts from transmission case.

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32.  Disconnect the manual valve link and remove the control valve body component.

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33.  Remove the check valve subcomponent and compression spring from transmission case.

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34.  Remove the transmission case gasket and brake drum gasket from transmission case.

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Caution
•  Be careful of the accumulator pistons A and B as they pop out.

35.  Blow compressed air from the oil passage shown in the figure and remove accumulator pistons A and B and the compression spring from the transmission case.

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36.  Using a flathead screwdriver, remove the snap ring from accumulator pistons A and B.

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37.  Remove the compression spring from accumulator piston A and B.

Caution
•  Do not damage the accumulator pistons.

38.  Using a flathead screwdriver, remove the O-ring from accumulator piston A and B.

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Caution
•  Be careful of the accumulator pistons C as they pop out.

39.  Blow compressed air from the oil passage shown in the figure and remove accumulator pistons C and the compression springs from the transmission case.

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40.  Using a flathead screwdriver, remove the O-ring from accumulator pistons C.

41.  Remove the accumulator valve and compression springs from the transmission case.

42.  Remove the bracket.

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43.  Remove the parking rod from the manual valve lever.

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44.  Pull out the shaft parking pawl and spring.

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Caution
•  Be careful not to apply too much force to the torsion spring.

45.  Using a flathead screwdriver, remove the driven plate from shaft parking pawl.

46.  Remove the parking pawl.

47.  Using a flathead screwdriver and hammer, remove the manual shaft washer.

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Caution
•  Do not damage the manual valve component.

48.  Using a hammer and pin punch, remove the pin.

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49.  Pull out the manual shaft and remove the manual valve component.

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50.  Using a flathead screwdriver, remove the oil seal.

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Caution
•  Do not damage the transmission case component.

51.  Remove the bolts from the oil pump as shown in the figure.

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52.  Using a flathead screwdriver, remove the oil pump.

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Caution
•  Do not damage the oil pump.

53.  Remove the O-ring from the oil pump.

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54.  Remove the thrust needle bearing and bearing race from oil pump.

55.  Remove the clutch drum component.

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56.  Remove the thrust needle bearing and bearing race from the clutch drum component.

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57.  Remove the thrust washer and F2 one-way clutch component from the clutch drum component.

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58.  Using a flathead screwdriver, remove the snap ring from the transmission case component.

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59.  Remove the retaining plates, drive and driven plates.

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60.  Inspect the lining of all drive plates.

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•  If the lining is flaking or has changed color, or if it is worn or the print mark is wearing away, replace with a new drive plate. When replacing, inspect the contact surfaces between the retaining plate, driven plate and drive plate. If they are scratched or have changed color, replace with new parts.
Note
•  Before replacing with new drive plates, soak them at least 2 h in ATF.

61.  Remove the snap ring from transmission case using snap ring pliers.

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62.  Remove the B2 brake piston component and F1 one-way clutch.

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63.  Remove the bearing race and thrust washer from the F1 one-way clutch component.

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64.  Remove the F1 one-way clutch component from the B3 brake piston component.

65.  Remove the front planetary gear component and thrust washer.

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66.  Remove the front and middle ring gear component.

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67.  Remove the bearing race and thrust needle bearing from front and middle ring gear component.

68.  Remove the retaining plates, drive and driven plates.

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69.  Inspect the lining of all drive plates.

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•  If the lining is flaking or has changed color, or if it is worn or the print mark is wearing away, replace with a new drive plate. When replacing, inspect the contact surfaces between the retaining plate, driven plate and drive plate. If they are scratched or have changed color, replace with new parts.
Note
•  Before replacing with new drive plates, soak them at least 2 h in ATF.

70.  Remove the middle planetary gear component and sun gear.

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71.  Remove the bearing race and thrust needle bearing from middle planetary gear component.

72.  Using a flathead screwdriver, remove the snap ring from transmission case component.

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73.  Remove the piston return spring and B1brake piston component.

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74.  Using a flathead screwdriver, remove the snap ring from transmission case.

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75.  Remove the driven plate.

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76.  Remove the retaining plates, drive and driven plates.

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77.  Remove the piston return spring.

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78.  Inspect the lining of all drive plates

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•  If the lining is flaking or has changed color, or if it is worn or the print mark is wearing away, replace with a new drive plate. When replacing, inspect the contact surfaces between the retaining plate, driven plate and drive plate. If they are scratched or have changed color, replace with new parts.
Note
•  Before replacing with new drive plates, soak them at least 2 h in ATF.

79.  Blow compressed air into the oil passage as shown in the figure while pressing the B2 brake piston component by hand and remove the B2 brake piston component from the transmission case.

Air pressure
392 kPa (4.0 kgf/cm2, 57 psi)
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80.  Remove the stopper spring from the transmission case.

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81.  Remove the snap ring from the transmission case using snap ring pliers.

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82.  Remove the following parts from the transmission case and disassemble in the order indicated below.

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(1)  Inner race
(2)  F3 one-way clutch
(3)  Rear ring gear component
(4)  Bearing race
(5)  Needle bearing
(6)  Bearing race
(7)  Intermediate shaft

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83.  Remove the retaining plates, drive and driven plates.

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84.  Inspect the lining of all drive plates.

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•  If the lining is flaking or has changed color, or if it is worn or the print mark is wearing away, replace it with a new drive plate. When replacing, inspect the contact surfaces between the retaining plate, driven plate and drive plate. If they are scratched or have changed color, replace with new parts.
Note
•  Before replacing with new drive plates, soak them at least 2 h in ATF.

85.  Remove the rear planetary gear component and bearing race and thrust needle bearing.

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86.  Remove the brake tube.

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Caution
•  Make sure that the snap ring is not expanded excessively.

87.  Compress the piston return spring using the SSTs and remove the snap ring.

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88.  Remove the piston return spring.

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89.  Blow compressed air into the oil passage as shown in the figure while pressing the B4 brake piston component by hand and remove the B4 brake piston component from the transmission case.

Air pressure
392 kPa (4.0 kgf/cm2, 57 psi)
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90.  Remove the inner brake piston and sleeve and B4 brake piston.

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91.  Remove the O-ring from the inner brake piston.

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92.  Remove the O-ring from sleeve.

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93.  Remove the O-ring from B4 brake piston.

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