Disassembly
SEPARATE BASIC SUBASSEMBLY1. REMOVE TRANSMISSION FROM TRANSAXLE
2. REMOVE NEUTRAL START SWITCH
3. REMOVE 4WD CHANGE-OVER SOLENOID
a. Remove the two bolts and solenoid.
b. Remove the two O-rings.
4. REMOVE SPEEDOMETER DRIVEN GEAR
5. REMOVE EXTENSION HOUSING AND GASKET
6. REMOVE INTERMEDIATE SHAFT
a. Remove the thrust bearing and two races.
b. Remove the intermediate shaft.
7. REMOVE PAN AND GASKET
CAUTION: Do not turn the transmission over as this will contaminate the valve body with foreign materials in the bottom of the pan.
a. Remove the seventeen bolts.
b. Remove the pan from the transmission case.
8. EXAMINE PARTICLES IN PAN
Remove the magnet and use it to collect any steel chips. Look carefully at the chips and particles in the pan and on the magnet to anticipate what type of wear you will find in the transmission:
Steel (magnetic) = bearing, gear and clutch plate wear.
Brass (nonmagnetic) = bushing wear.
9. TURN TRANSMISSION OVER AND REMOVE TUBES
Pry up both tube ends with a large screwdriver and remove the tubes.
10. REMOVE STRAINER
11. REMOVE VALVE BODY
a. Remove the fourteen bolts.
b. Remove the six steel balls.
c. Remove the valve vibrating stopper.
12. REMOVE ACCUMULATOR PISTONS AND SPRINGS
WARNING: Keep face away to avoid injury. Do not use regular high-pressure air.
Position a rag to catch each piston. Using low-pressure compressed air (1 kg/sq.cm , 14 psi or 98 kPa max.) pop each piston into the rag. Force air into holes shown, and remove the pistons and springs.
13. REMOVE PARKING LOCK ROD
14. REMOVE SPRING, PIVOT PIN AND PARKING LOCK PAWL
15. REMOVE SPACER
Unstake the spacer and turn the ring 90 °
16. DRIVE OUT SLOTTED SPRING PIN AND REMOVE MANUAL VALVE LEVER SHAFT
Using a hammer and punch, drive out the slotted spring pin.
17. REMOVE OIL PUMP SUCTION TUBE
After removing the bracket bolt, remove the pump suction tube.
18. REMOVE OIL PUMP DELIVERY TUBE AND PRESSURE TUBE
Pry up both tube ends with a large screwdriver and remove the tubes.
19. REMOVE OIL PUMP
a. Loosen the three bolts, but do not remove them.
b. Remove the seven bolts and pull out the oil pump.
20. REMOVE INPUT SHAFT, DRIVEN SPROCKET AND CHAIN
a. Remove the snap ring.
b. Remove both sprockets, pulling them out uniformly.
21. PLACE TRANSMISSION CASE ON WOODEN BLOCK AND REMOVE FRONT SUPPORT
22. MEASURE DISTANCE BETWEEN TOP OF CASE AND FRONT CLUTCH
Make a note of the distance for reassembly.
SST 09350-20015 (09370-12010)
Height: 0.6 - 1.6 mm (0.024 - 0.063 in.)
23. REMOVE FRONT CLUTCH AND BEARINGS
Grasp the shaft and pull out the front clutch assembly. Be careful of bearings and races on both sides of the assembly.
24. REMOVE OUTPUT SHAFT AND FRONT PLANETARY GEAR
25. REMOVE REAR CLUTCH
Grasp the clutch hub and pull it out from the case.
26. REMOVE CENTER SUPPORT BOLTS
Remove the two center support bolts.
27. REMOVE CENTER SUPPORT AND SUN GEAR ASSEMBLY
From the case front opening, grasp the assembly and pull it out.
28. REMOVE REACTION PLATE RETAINING RING
Using a long screwdriver, compress the snap ring and lift it above the groove with a wire hook.
29. REMOVE REAR NO.2 ONE-WAY CLUTCH AND REAR PLANETARY GEAR
30. REMOVE BRAKE NO.3 DISC, PLATE AND CUSHION PLATE
31. REMOVE REAR PLANETARY RING GEAR
32. BASIC DISASSEMBLY IS COMPLETE
The transmission in now in basic component subassemblies. Next, you will disassemble, clean, inspect, repair and assemble each of these component groups.