Part 1

GENERAL NOTES:
The automatic transmission is composed of highly precision-finished parts, necessitating careful inspection before reassembly because even a small nick could cause fluid leakage or affect performance. The instructions here are organized so that you work on only one component group at a time. This will help avoid confusion from similar-looking parts of different sub-assemblies being on your workbench at the same time. The component groups are inspected and repaired from the converter housing side. As much as possible, complete the inspection, repair and reassembly before proceeding to the next component group. If a defect is found in a certain component group during reassembly, inspect and repair this group immediately. If a component group cannot be assembled because parts are being ordered, be sure to keep all parts of that group in a separate container while proceeding with disassembly, inspection, repair and reassembly of other component groups.

Recommended ATF: Type T-IV (TSB - T003-99 5/21/99)

General Cleaning Notes:
a. All disassembled parts should be washed clean and any fluid passages and holes should be blown through with compressed air.
b. Dry all parts with compressed air-never use shop rags.
c. When using compressed air, always aim away from yourself to prevent accidentally spraying automatic transmission fluid or kerosene on your face.
d. The recommended automatic transmission fluid or kerosene should be used for cleaning.

Parts Arrangement
a. After cleaning, the parts should be arranged in the correct order to allow efficient inspection, repairs, and reassembly.
b. When disassembling a valve body, be sure to keep each valve together with the corresponding spring.
c. New discs for the brakes and clutches that are to be used for replacement mist be soaked in transmission fluid for at least 15 minutes before reassembly.

General Reassembly:
a. All oil seal rings, clutch discs, clutch plates, rotating parts, and sliding surfaces should be coated with transmission fluid prior to reassembly.
b. All gaskets and rubber O-rings should be replaced.
c. Do not use adhesive cements on gaskets and similar parts.
d. Make sure that the ends of a snap ring are not aligned with one of the cutouts and are installed in the groove correctly.
e. If a worn bushing is to be replaced, the subassembly containing that bushing must also be replaced.
f. Check thrust bearings and races for wear or damage. Replace if necessary.
g. Use petroleum jelly to keep parts in place.
h. When working with FIPG material, you must observe the following.
- Using a razor blade and gasket scraper, remove all the old packing (FIPG) material from the gasket surfaces.
- Thoroughly clean all components to remove all the loose material.
- Clean both sealing surfaces with a non-residue solvent.
- Parts must be reassembled within 10 minutes of application. Otherwise, the packing (FIPG) material must be removed and reapplied.

BEARING AND RACES INSTALLATION POSITION AND DIRECTION





COMPONENTS








DISASSEMBLY



1. REMOVE CONTROL SHAFT LEVER
Remove the nut, washer and control shaft lever.





2. REMOVE [1][2]PARK/NEUTRAL POSITION SWITCH
a. Using a screwdriver, unstake the lock washer.
b. Remove the lock washer, nut and bolt.
c. Remove the [1][2]park/neutral position switch.





3. REMOVE UNION AND ELBOW
a. Remove the union and elbow.
b. Remove the 2 O-rings from the union and elbow.





4. REMOVE SPEED SENSOR
a. Remove the 2 bolts and 2 speed sensors.
b. Remove the O-ring from each one.





5. REMOVE TRANSMISSION HOUSING
a. LS400: Remove the bolt and the breather pipe.
b. GS300/400: Remove the bolt and breather hose.
c. SC400: Remove the breather plug.





d. Remove the 6 bolts.
e. Remove the transmission housing.





6. REMOVE TRANSMISSION OUTPUT FLANGE
a. Using a hammer and chisel, loosen the staked part of the nut.

HINT: Shift the manual valve lever to the P position.





b. Using a deeper socket wrench of 30 mm, remove the nut.





c. Remove the output flange.





d. Remove the oil seal from the output flange.





7. REMOVE EXTENSION HOUSING
a. Remove the 6 bolts.
b. Remove the extension housing.

HINT: Using a brass bar and hammer.

c. Remove the gasket from the extension housing.





8. REMOVE VEHICLE SPEED SENSOR ROTOR
Remove the 2 washers and vehicle speed sensor rotor from the output shaft.





9. REMOVE ONE-WAY CLUTCH
a. Using SST, remove the snap ring.
SST 09350-30020 (09350-07070)





b. Remove the No.2 one-way clutch and the retainer.





10. INSTALL TRANSMISSION CASE ON OVERHAUL ATTACHMENT
11. REMOVE OIL PAN

NOTICE: Do not turn the transmission over as this will contaminate the valve body with any foreign matter at the bottom of the pan.

a. Remove the 19 bolts.





b. Insert the blade of SST between the transmission case and oil pan, cut off applied sealer.
SST 09032-00100

NOTICE: Be careful not to damage the oil pan flange.





12. EXAMINE PARTICLES IN PAN
Remove the magnets and use them to collect steel particles.
Carefully lock at the foreign matter and particles in the pan and on the magnets to anticipate the type of wear you will find in the transmission.
- Steel (magnetic): bearing, gear and clutch plate wear
- Brass (nonmagnetic): bushing wear





13. REMOVE OIL STRAINER
a. Turn over the transmission.
b. Remove the 4 bolts holding the oil strainer to the valve body.





c. Remove the 3 gaskets from the oil strainer.





14. REMOVE TRANSMISSION WIRE
a. Remove the ATF temperature sensor.
b. Remove the bolt and clamp.
c. Disconnect the 7 connectors from the shift solenoid valves.





d. Remove the bolt and stopper plate from the case.
e. Pull the transmission wire out of the transmission case.
f. Remove the O-ring from the grommet.





15. REMOVE VALVE BODY
a. Remove the 20 bolts.
b. Remove the valve body.





16. REMOVE CHECK BALL BODY
Remove the check ball body and spring.





17. REMOVE ACCUMULATOR SPRING AND PISTON
a. Applying compressed air to the oil hole, remove the B2 and C2 accumulator pistons and springs.
b. Remove the O-rings from each pistons.

NOTICE: Take care as the B0 and C0 accumulator piston may jump out.





c. Applying compressed air to the oil hole, remove the B0 accumulator piston and spring.
d. Remove the O-rings from the piston.

NOTICE: Take care as the C0 accumulator piston may jump out.





e. Applying compressed air to the oil hole, remove the C0 accumulator piston and spring.

HINT: The C0 accumulator piston is deviated in 2 parts, so if only the top part is removed, after removing the spring reapply compressed air to remove the bottom part.

f. Remove the O-rings from the piston.





18. REMOVE PARKING LOCK ROD AND PAWL
a. Remove the 3 bolts and parking lock pawl bracket.





b. Disconnect the parking lock rod from the manual valve lever.





c. Pull out the parking lock pawl shaft from the front side, then remove the lock pawl and spring.
d. Remove the E-ring from the shaft.





19. REMOVE MANUAL VALVE LEVER SHAFT
a. Using a hammer and screwdriver, cut off the spacer and remove it from the shaft.





b. Using a pin punch and hammer, drive out the spring pin.

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.





20. REMOVE OIL PUMP
a. Remove the 7 bolts holding the oil pump to the transmission case.





b. Using SST, remove the oil pump.
SST 09350-30020 (09350-07020)





c. Remove the race from the oil pump.
d. Remove the O-ring from the oil pump.





21. REMOVE O/D PLANETARY GEAR UNIT WITH O/D DIRECT CLUTCH
a. Remove the O/D planetary gear with the O/D direct clutch from the transmission case.





b. Remove the race and assembled bearing & race.





22. REMOVE O/D PLANETARY RING GEAR
a. Remove the O/D planetary ring gear from the transmission case.





b. Remove the bearing and 2 races from the planetary ring gear.





23. CHECK PISTON STROKE OF O/D BRAKE
a. Place SST and dial indicator onto the O/D brake piston.
SST 09350-30020 (09350-06120)





b. Measure the stroke while applying and releasing compressed air (392 kPa, 4 kgf/cm2, 57 psi).

Piston stroke:
1UZ-FE: 1.40 - 1.70 mm (0.055 - 0.067 inch)
2JZ-GE: 1.32 - 1.62 mm (0.052 - 0.064 inch)

If the stroke is non-standard, inspect the discs.





24. REMOVE FLANGE, PLATE AND DISC OF O/D BRAKE
a. Using a screwdriver, remove the snap ring.





b. Remove the O/D brake pack as a set.

HINT:
1UZ-FE: 2 flange, 3 plates and 4 discs
2JZ-GE: 2 flange, 2 plates and 3 discs

c. Remove the spring from the case.





25. REMOVE O/D SUPPORT ASSEMBLY
a. Remove the 2 bolts holding the O/D support assembly from the case.





b. Using SST, remove the snap ring.
SST 09350-30020 (09350-07060)





c. Using SST, remove the O/D support assembly.
SST 09350-30020 (09350-07020)





d. Remove the assembled bearing & race and race from the O/D support.





26. CHECK PISTON ROD STROKE OF 3RD COAST BRAKE
a. Using a water proof pen, place a mark in the 3rd coast brake piston rod, as shown in the illustration.





b. Using SST, measure the stroke while applying compressed air (392 kPa, 4 kgf/cm2, 57 psi).
SST 09240-00020

Piston rod stroke: 2.0 - 3.0 mm (0.079 - 0.118 inch)

If the stroke is non-standard, inspect the brake band.





27. REMOVE 3RD COAST BRAKE COVER, PISTON ASSEMBLY AND SPRING
a. Using SST, remove the snap ring.
SST 09350-30020 (09350-07060)





b. Applying compressed air to the oil hole, remove the 3rd coast brake cover, piston assembly and spring.
c. Remove the 2 O-rings from the cover.





28. REMOVE DIRECT CLUTCH WITH FORWARD CLUTCH
a. Remove the direct clutch with forward clutch from the case.





b. Remove the direct clutch from the forward clutch.





c. Remove the assembled bearing & race, thrust washer and race from the forward clutch.





29. REMOVE 3RD COAST BRAKE BAND
a. Using a screwdriver, remove the E-ring from the pin.

HINT: Apply the grease to the E-ring and pin before the work so that the ring does not fly out.

b. Remove the pin from the brake band.
c. Remove the E-ring from the pin.





d. Remove the 3rd coast brake band from the case.