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.



DISASSEMBLY



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





2. REMOVE PARK/NEUTRAL POSITION SWITCH
a. Using a screwdriver, unstake the lock washer.
b. Remove the lock washer, nut and bolt.
c. Remove the 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.