Overhaul (Disassembly)
DisassemblyCAUTION:
^ Do not disassemble parts behind Drum Support.
^ When replacing the control valve assembly, erase EEP ROM in TCM. Refer to "Precautions for A/T Assembly and Control Valve Assembly Replacement".
1. Drain ATF through drain hole.
2. Remove torque converter by holding it firmly and turning while pulling straight out.
3. Check torque converter one-way clutch using check tool as shown in the figure.
a. Insert check tool into the groove of bearing support built into one-way clutch outer race.
b. When fixing bearing support with check tool, rotate one-way clutch spline using screwdriver.
c. Check that inner race rotates clockwise only If not, replace torque converter assembly.
4. Remove converter housing from transmission case.
CAUTION: Be careful not to scratch converter housing.
5. Remove O-ring from input clutch assembly
6. Remove tightening bolts for oil pump assembly and transmission case.
7. Attach sliding hammer to oil pump assembly and extract it evenly from transmission case.
CAUTION:
^ Fully tighten sliding hammer screw.
^ Make sure that bearing race is installed to the oil pump assembly edge surface.
8. Remove O-ring from oil pump assembly.
9. Remove bearing race, needle bearing and front sun gear from transmission case.
NOTE: Remove front sun gear by rotating left/right.
10. Remove seal rings from input clutch assembly.
11. Remove front carrier assembly from transmission case. (With input clutch assembly and rear internal gear.)
CAUTION: Be careful to remove it with needle bearing.
12. Loosen lock nut and remove band servo anchor end pin from transmission case.
13. Remove brake band from transmission case.
^ To prevent brake linings from cracking or peeling, do not stretch the flexible band unnecessarily. When removing the brake band, always secure it with a clip as shown in the figure at left.
Leave the clip in position after removing the brake band.
^ Check brake band facing for damage, cracks, wear or burns.
14. Remove mid carrier assembly and rear carrier assembly as a unit.
15. Remove mid carrier assembly from rear carrier assembly.
16. Remove needle bearing (front side) from mid carrier assembly
17. Remove needle bearing (rear side) from mid carrier assembly.
18. Remove needle bearing from rear carrier assembly
19. Remove bearing race from rear carrier assembly
20. Remove mid sun gear assembly, rear sun gear assembly and high and low reverse clutch hub as a unit.
CAUTION: Be careful to remove then with bearing race and needle bearing.
21. Remove high and low reverse clutch assembly from transmission case.
CAUTION: Make sure that needle bearing is installed to the high and low reverse clutch assembly edge surface.
22. Remove direct clutch assembly from transmission case.
23. Remove needle bearing from drum support edge surface.
24. Remove oil pan and oil pan gasket.
25. Check foreign materials in oil pan to help determine causes of malfunction. If the fluid is very dark, smells burned, or contains foreign particles, the frictional material (clutches, band) may need replacement. A tacky film that will not wipe clean indicates varnish build up. Varnish can cause valves, servo, and clutches to stick and can inhibit pump pressure.
^ If frictional material is detected, replace radiator after repair of A/T. Refer to "RADIATOR", "RADIATOR (ALUMINUM TYPE)".
26. Disconnect terminal cord assembly connectors.
CAUTION: Be careful not to damage connector.
27. Disconnect fluid temperature sensor 2 connector.
CAUTION: Be careful not to damage connector.
28. Remove terminal cord assembly connectors from bracket.
CAUTION: Be careful not to damage connector.
29. Disconnect revolution sensor connector.
CAUTION: Be careful not to damage connector.
30. Straighten terminal clips to free terminal cord assembly and revolution sensor harness then remove terminal clips.
CAUTION: Hang down terminal cord assembly and revolution sensor harness toward outside so as not to disturb removal of control valve assembly.
31. Remove bolts A, B and C from control valve assembly
32. Remove control valve assembly from transmission case.
CAUTION: When removing, be careful with the manual valve notch and manual plate height. Remove it vertically.
33. Remove fluid temperature sensor 2 with bracket from control valve assembly.
34. Remove bracket from fluid temperature sensor 2.
35. Remove tightening bolts for output shaft & companion flange complement and transmission case.
36. Tap output shaft & companion flange complement with soft hammer.
37. Remove output shaft & companion flange complement from transmission case. (With needle bearing)
38. Remove intermediate shaft from transmission case by rotating left/right.
39. Remove needle bearing from transmission case.
40. Remove revolution sensor from transmission case.
CAUTION: Be careful not to damage harness with the edge of case.
41. Remove reverse brake snap ring (fixing plate) using 2 flatbladed screwdrivers.
NOTE: Press out snap ring from the transmission case oil pan side gap using a flat-bladed screwdriver, and remove it using another screwdriver.
42. Remove reverse brake retaining plate, drive plate, driven plate and dish plate from transmission case.
CAUTION: Be careful to remove it with N-spring.
43. Remove snap ring (fixing spring retainer) using a flat-bladed screwdriver.
44. Remove spring retainer and return spring from transmission case.
45. Remove seal rings from drum support.
46. Remove reverse brake piston from transmission case.
47. Remove lip seal and D-ring from reverse brake piston.
48. Remove terminal cord assembly connectors from bracket.
CAUTION: Be careful not to damage connector.
49. Remove terminal cord assembly from transmission case.
50. Use a pin punch (4mm dia. commercial service tool) to knock out retaining pin.
51. Remove manual shaft retaining pin with nippers.
52. Remove manual plate (with parking rod) from manual shaft.
53. Remove parking rod from manual plate.
54. Remove manual shaft from transmission case.
55. Remove manual shaft oil seal using a flat-bladed screwdriver.
CAUTION: Be careful not to scratch transmission case.
56. Remove detent spring and spacer from transmission case.
57. Remove snap ring from transmission case using snap ring pliers.
58. Remove servo assembly from transmission case.
59. Remove return spring from servo assembly.
60. Remove O-rings from servo assembly.
61. Remove parking actuator support from output shaft & companion flange complement.
62. Remove parking pawl, parking pawl shaft and return spring from output shaft & companion flange complement.
63. Remove return spring from parking pawl.