Overhaul
CAUTION Before disassembling the planetary gearbox, remove the valve body and extract the sealing plugs that have O-rings.DISASSEMBLY AND ASSEMBLY WORK SEQUENCE
Disassembly
- Remove end cover using screwdriver.
- Remove bolts for ATF pump.
- Thread Me bolts into tapped holes in ATF pump, and remove ATF pump, refer to Fig. 2, below.
- Remove all clutches with support tube, B2 plates, springs and spring caps, refer to Fig. 3, below.
- Remove bolt for small drive shaft, refer to Fig. 4, below.
- Remove small drive shaft and bearing.
- Pull out large drive shaft, refer to Fig. 5, below.
- Remove large sun gear, refer to Fig. 6, below.
- Remove circlips for one-way clutch and support tube, then remove one-way clutch, refer to Fig. 7, below.
- Remove planet carrier with spring plate, refer to Fig.8, below.
- Remove B1 plates.
Assembling
NOTE: When the planet carrier is replaced, it must also be adjusted, refer to Planetary Gears A/T. Adjustments
- Place axial needle bearing with washers in drive gear.
- Install planet carrier, refer to Fig. 9, below.
- Install small sun gear.
- Install axial needle bearing and washer in planet carrier.
- Install splined plates and spring plate, refer to Fig. 10, below.
NOTE: When replacing the one-way clutch, the B1 piston or the plates, the reverse gear brake B1 must be adjusted, refer to Clutch A/T. Adjustments
- Install one-way clutch, refer to Fig. 11, below.
- Install circlips for one-way clutch and support tube, refer to Fig.12, below.
- Install large sun gear, refer to Fig. 13, below.
- Install axial needle bearing and washers on large sun gear.
- Install large drive shaft, refer to Fig. 14, below.
- Install axial needle bearing and needle bearing for small drive shaft.
- Install small drive shaft, refer to Fig. 15, below.
- Tighten bolt with shim and washer.
- Check measurement, refer to Planetary Gears A/T. Adjustments
- Install axial needle bearing for K3, with washer.
- Install 3rd and 4th gear clutch K3, refer to Fig.16, below.
CAUTION: Make sure that the piston rings are seated correctly.
- Install axial needle bearing and shims for K1.
- Install 1st to 3rd gear clutch K1, refer to Fig. 17, below.
- Install shim(s) for clutches.
NOTE: When replacing K1, K2 or the ATF pump, determine new shim thickness, refer to Clutch A/T. Adjustments
- Install reverse clutch K2 and support tube, refer to Fig. 18, below.
- Install plates and then springs, refer to Fig.s 19 and 20, below.
NOTE: When replacing support tube or ATF pump, 2nd and 4th gear brake B2 must be adjusted, refer to Clutch A/T. Adjustments
- Install wavy spring washer.
- Install gasket for transmission housing.
- Install O-ring on ATF pump.
- Install ATF pump, refer to Fig. 21, below.
- Tighten ATF pump bolts.
- Carry out clutch play check measurement, refer to Clutch A/T. Adjustments
- Install sealing plugs, valve body and ATF oil pan, refer to item 12 in illustration found in Valve Body Replacement. Service and Repair
- Install end cover using special tool 40-20.
ILLUSTRATIONS
1. End Cover
- Remove using screwdriver
- Install using special tool 40-20
2. Bolt
- For small drive shaft
- Engage parking lock to remove or install
- Removing, refer to Fig. 4, below
- Installing, refer to Fig. 15, below
- Tighten to: 30 Nm (22 ft lb)
3. Washer
4. Shim For Planet Carrier
- Determining thickness, refer to Planetary Gears A/T. Adjustments
- To adjust planet carrier, remove input gear, refer to Differential Automatic Transaxle. Service and Repair
5. Transmission Housing
- Removing and installing valve body, refer to Valve Body. Service and Repair
- Disassembling and assembling final drive, refer to Differential Automatic Transaxle. Service and Repair
- Mounting transmission on repair stand, refer to Fig. 1, below
6. Washer
- Lugs face toward axial needle bearing
7. Axial Needle Bearing
- Install in planet carrier with washers
8. Washers
9. O-ring
- Always replace
- Install in planet carrier
10. Planet Carrier
- Lightly grease washers and needle bearing and install on planet carrier, then install planet carrier and plates.
11. Shim
- Determining thickness, refer to Clutch A/T. Adjustments
12. Inner Splined Plate (B1)
- Number of plates, refer to Code Letters, Engine/transaxle Applications, Ratios And Equipment. Application and ID
- Soak new plates in ATE for 15 minutes before installing
13. Outer Splined Plate (B1)
- Number of plates, refer to Code Letters, Engine/transaxle Applications, Ratios And Equipment. Application and ID
14. Thrust Plate
- Install with flat side toward splines
15. Plate Spring
- Curved side faces toward one-way clutch
16. One-Way Clutch With B1 Piston
- Removing, refer to Fig. 7, below
- Installing, refer to Fig. 11, below
NOTE: Before removing or installing the one-way clutch, remove the valve body and sealing plugs.
17. Circlip
- For one-way clutch
- Removing, refer to Fig. 7, below
- Installing, refer to Fig. 12, below
18. Oil Baffle
- Install in groove in transmission housing in front of ATE vent
19. Circlip
- For support tube
- Removing, refer to Fig. 7, below
- Installing, refer to Fig. 12, below
20. Small Sun Gear
- Removing, refer to Fig. 8, below
- Installing in planet carrier Fig. 9, below
21. Washer
- Install with rounded side facing toward small sun gear
22. Axial Needle Bearing
23. Large Sun Gear
- Removing, refer to Fig. 6, below
- Installing, refer to Fig. 13, below
24. Washer
- Install with chamfered side facing large sun gear
25. Axial Needle Bearing
26. Large Drive Shaft
- Removing, refer to Fig. 5, below
- Installing in planet carrier Fig. 14, below
27. Axial Needle Bearing
28. Needle Bearing
29. Small Drive Shaft
- Removing, refer to Fig. 4, below
- Installing, refer to Fig. 15, below
30. Axial Needle Bearing
- With integral washer
- Always install with bearing toward small drive shaft
31. 3rd And 4th Gear Clutch K3 With Pump Shaft
- Removing, refer to Fig. 3, below
- Installing, refer to Fig. 16, below
32. Washer
- Install with lugs facing toward axial needle bearing
33. Axial Needle Bearing
34. Washer
35. 1st To 3rd Gear Clutch K1 With Turbine Shaft
- Removing, refer to Fig. 3, below
- Installing, refer to Fig. 17, below
36. Shim
- Determining thickness, refer to Clutch A/T. Adjustments
37. Shim
- Determining thickness, refer to Clutch A/T. Adjustments
- Use 1 or 2 shims depending on dimensions (a 2nd shim - 37 may not be required)
38. Reverse Clutch K2
- Removing, refer to Fig. 3, below
- Installing, refer to Fig. 18, below
39. Support Tube
- Removing, refer to Fig. 3, below
- Installing, refer to Fig. 18, below
- Install so that groove engages in wedge of one-way clutch
40. Outer Splined Plate (B2)
- Number of plates, refer to Code Letters, Engine/transaxle Applications, Ratios And Equipment. Application and ID
- Removing, refer to Fig. 3, below
- Always install an outer plate of 3 mm thickness, refer to Fig. 19, below
41. Inner Splined Plate (B2)
- Number of plates, refer to Code Letters, Engine/transaxle Applications, Ratios And Equipment. Application and ID
- Soak new plates in ATE for 15 minutes before installing
- Removing, refer to Fig. 3, below
- Installing, refer to Fig. 9, below
42. Outer Splined Plate (B2)
- Number of plates, refer to Code Letters, Engine/transaxle Applications, Ratios And Equipment. Application and ID
- Always install an outer plate of 2 mm thickness
- Removing, refer to Fig. 3, below
- Installing, refer to Fig. 19, below
43. Outer Splined Plate (B2)
- Number of plates, refer to Code Letters, Engine/transaxle Applications, Ratios And Equipment. Application and ID
- Determining thickness, refer to Clutch A/T. Adjustments
- Removing, refer to Fig. 3, below
- Installing, refer to Fig. 20, below
44. Spring Cap
- Qty: 3
- Install after installing first outer splined plate
45. Spring
- Qty: 3
- Install before installing last outer splined plate
- Installing, refer to Fig. 20, below
46. Spring Cap
- Qty: 3
- Install before installing last outer splined plate, refer to Fig. 20, below
- Installing, refer to Fig. 20, below
47. Wavy Spring Washer
48. Gasket
- Always replace
49. O-ring
- Always replace
- Install on ATF pump
50. ATF Pump With B2 Piston
- Removing, refer to Fig. 2, below
- Installing, refer to Fig. 21, below
51. Bolt
- Tighten to 10 Nm (84 inch lbs) plus additional 1/4-turn (90°)
- Additional 1/4-turn can be completed in several stages
Fig. 1 Mounting Transmission On Repair Stand
Fig. 2 Removing ATF Pump
- Install 8 mm bolts (A in illustration) into threaded holes in ATF pump.
- Press pump off transmission housing by turning bolts (A in illustration).
Fig. 3 Removing Clutches Together With Support Tube, B2 Plates, Springs And Spring Caps
Fig. 4 Removing Bolt For Small Drive Shaft
- Engage parking lock.
- Insert screwdriver through holes in large drive shaft and into large sun gear.
- Remove bolt for small drive shaft (behind end cover) and remove drive shaft.
Fig. 5 Removing Large Drive Shaft
Fig. 6 Removing Large Sun Gear
Fig. 7 Removing Circlips For One-way Clutch And Support Tube
- After removing circlips, pull one-way clutch out of transmission housing using pliers applied on retainer (arrow in illustration).
Fig. 8 Removing Planet Carrier Together With Small Sun Gear
- Remove planet carrier with spring plate.
- Remove B1 plates.
Fig. 9 Placing Planet Carrier With Bearing In Drive Gear
NOTE: Insert O-ring in planet carrier before installing.
- Insert small sun gear and axial needle bearing for large sun gear (arrow in illustration) in planet carrier.
Fig. 10 Installing Inner And Outer Splined Plates And B1 Spring Plate
- When one-way clutch, B1 piston or splined plates are replaced, reverse brake B1 must be adjusted.
Fig. 11 Installing One-way Clutch
- Place assembly ring 3267 in one-way clutch and preload needles.
Fig. 12 Installing Circlips For Ore-way Crutch And Support Tube
Fig. 13 Installing Large Sun Gear
Fig. 14 Installing Large Drive Shaft
Fig. 15 Installing Small Drive Shaft
- Install axial needle bearing and needle bearing before installing small drive shaft.
- Install bolt for small drive shaft with washer and shim.
Tightening to: 30 Nm (22 ft lb)
- Check measurement, refer to Adjusting planet carrier.
Fig. 16 Installing 3rd And 4th Gear Clutch K3
Fig. 17 Installing 1st To 3rd Gear Clutch K1
- Install shim(s) in K1.
Fig. 18 Installing Reverse Gear Clutch K2 And Support Tube
- Place reverse gear clutch K2 on shim(s) and install support tube (arrow) so that groove engages wedge of one-way clutch.
Fig. 19 Installing B2 Plates
- Install 3 mm thick outer splined plate, then install 3 spring caps.
- Install all inner and 2 mm thick outer splined plates.
- Install 3 springs and spring caps before installing last outer splined plate.
Fig. 20 Installing Spring Caps And Last Outer Plate
NOTE: When replacing support tube or ATF pump, adjust 2nd and 4th gear brake B2.
Fig. 21 Installing ATF Pump
NOTE:
^ Tighten bolts evenly, alternating in a diagonal pattern.
^ Make sure that the O-ring is not damaged.