Part 2

AUTOMATIC TRANSMISSION UNIT

COMPONENTS:

DISASSEMBLY (STEPS 25 - 74)

25. REMOVE PARKING LOCK PAWL BRACKET
a. Remove the 3 bolts and the parking lock pawl bracket.

26. REMOVE PARKING LOCK ROD SUB-ASSEMBLY
a. Disconnect the parking lock rod from the manual valve lever.

27. REMOVE PARKING LOCK PAWL SHAFT
a. Pullout the parking lock pawl shaft from the front side, then remove the lock pawl and the spring.
b. Remove the E-ring from the shaft.

28. REMOVE MANUAL VALVE LEVER SUB-ASSEMBLY

a. Using a hammer and a screwdriver, cut off the spacer and remove it from the shaft.

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

HINT:
Slowly drive out the spring pin so that 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.

29. REMOVE MANUAL VALVE LEVER SHAFT OIL SEAL
a. Using a screwdriver, remove the 2 oil seals.

30. REMOVE OIL PUMP ASSEMBLY

a. Remove the 10 bolts from the transmission case.

b. Using a screwdriver with its tip wrapped with tape, pull out the oil pump.

NOTICE: Do not damage the oil pump.

c. Remove the thrust bearing race No. 1 from the oil pump.
d. Remove the O-ring from the oil pump.

31. REMOVE CLUTCH DRUM AND INPUT SHAFT

a. Remove the clutch drum and input shaft from the transmission case.

b. Remove the clutch drum thrust washer, 2 thrust needle roller bearings and bearing race.

32. INSPECT 1 WAY NO. 2 CLUTCH ASSEMBLY

33. REMOVE 1 WAY NO. 2 CLUTCH ASSEMBLY
a. Remove the 1 way No. 2 clutch assembly and clutch drum thrust washer from the clutch drum and input shaft.

34. REMOVE BRAKE NO. 3 SNAP RING
a. Using a screwdriver, remove the brake No. 3 snap ring from the transmission case.

35. REMOVE 2ND BRAKE DISC SET
a. Remove the flange, cushion plate, 4 discs and 4 plates from the transmission case.

36. INSPECT 2ND BRAKE DISC SET

37. REMOVE 2ND BRAKE PISTON HOLE SNAP RING
a. Using SST, remove the snap ring.
SST 09350-30020 (09350-07060)

38. REMOVE 1 WAY CLUTCH ASSEMBLY
a. Remove the 1 way clutch assembly and the planetary carrier thrust washer No. 1 from the transmission case.

39. REMOVE 2ND BRAKE CYLINDER
a. Remove the 2nd brake cylinder from the transmission case.

40. REMOVE 2ND BRAKE PISTON

a. Using SST and a press, remove the 2nd brake piston snap ring.
SST 09351-40010 (09351-04060, 09351-04070)
b. Remove the brake piston return spring subassembly No. 3.

c. Hold the 2nd brake piston and apply compressed air (392 kPa, 4.0 kgf/cm2, 57 psi) to the 2nd brake cylinder to remove the 2nd brake piston.

d. Remove the 2 O-rings from the 2nd brake piston.

41. INSPECT BRAKE PISTON RETURN SPRING SUB-ASSEMBLY NO. 3
42. REMOVE FRONT PLANETARY GEAR ASSEMBLY

a. Remove the front planetary gear assembly and the 1 way clutch inner race from the transmission case.

b. Remove the thrust needle roller bearing, the thrust bearing race No. 3 and the planetary carrier thrust washer No. 2 from the transmission case.

43. INSPECT FRONT PLANETARY GEAR ASSEMBLY
44. INSPECT 1 WAY CLUTCH ASSEMBLY

45. REMOVE FRONT PLANETARY RING GEAR
a. Remove the front planetary ring gear from the transmission case.

46. REMOVE CENTER PLANETARY RING GEAR

a. Using a screwdriver, remove the snap ring.

b. Remove the center planetary ring gear and the front planetary ring gear flange from the front planetary ring gear.
c. Remove the thrust needle roller bearing from the front planetary ring gear flange.

47. REMOVE BRAKE DISC NO. 1
a. Remove the flange, the 3 discs and the 3 plates from the transmission case.

48. INSPECT BRAKE DISC NO. 1

49. REMOVE BRAKE PISTON RETURN SPRING SNAP RING
a. Using a screwdriver, remove the brake piston return spring snap ring from the transmission case.

50. REMOVE BRAKE PISTON RETURN SPRING SUB-ASSEMBLY
a. Remove the brake piston return spring and the brake piston No. 1 with the brake cylinder No. 1 from the transmission case.

51. INSPECT BRAKE PISTON RETURN SPRING SUB-ASSEMBLY

52. REMOVE BRAKE PISTON NO. 1
a. Hold the brake cylinder No. 1 and apply compressed air (392 kPa, 4 kgf/cm2, 57 psi) to the brake cylinder No. 1 to remove the brake piston No. 1.

HINT:
If the piston does not pop out with compressed air, lift the piston out with needle-nose pliers.

b. Remove the 2 O-rings from the brake piston No. 1.

53. REMOVE BRAKE DISC NO. 2

a. Using a screwdriver, remove the brake No. 2 snap ring from the transmission case.

b. Remove the 2 flanges, the brake piston return spring, the 4 discs and the 3 plates from the transmission case.

54. INSPECT BRAKE DISC NO. 2
55. INSPECT BRAKE PISTON RETURN SPRING SUB-ASSEMBLY NO. 2

56. REMOVE BRAKE PISTON NO. 2
a. Hold the brake piston No. 2 and apply compressed air (392 kPa, 4 kgf/cm2, 57 psi) to the transmission case to remove the brake piston No. 2 with the cylinder.

HINT:
If the piston does not pop out with compressed air, lift the piston out with needle-nose pliers.

b. Remove the piston from the cylinder.
c. Remove the 2 O-rings from the brake piston No. 2.

57. REMOVE CENTER PLANETARY GEAR ASSEMBLY
a. Remove the center planetary gear assembly, the planetary sun gear and the thrust bearing race No. 4 from the transmission case.

58. INSPECT CENTER PLANETARY GEAR ASSEMBLY
59. REMOVE INTERMEDIATE SHAFT

a. Using SST, remove the snap ring from the transmission case.
SST 09350-30020 (09350-07060)

b. Remove the intermediate shaft with the 1 way No. 3 clutch assembly from the transmission case.

60. INSPECT 1 WAY NO. 3 CLUTCH ASSEMBLY

61. REMOVE 1 WAY NO. 3 CLUTCH ASSEMBLY
a. Remove the 1 way clutch No. 3 assembly and the 1 way clutch inner race from the intermediate shaft.

62. REMOVE REAR PLANETARY RING GEAR FLANGE SUB-ASSEMBLY
a. Remove the thrust bearing race No.8, the thrust needle roller bearing, the thrust bearing race No.7 and the planetary ring gear flange from the intermediate shaft.

63. INSPECT REAR PLANETARY RING GEAR FLANGE SUB-ASSEMBLY
64. INSPECT INTERMEDIATE SHAFT

65. REMOVE BRAKE PLATE STOPPER SPRING
a. Remove the brake plate stopper spring from the transmission case.

66. REMOVE BRAKE DISC NO. 4
a. Remove the sleeve, 4 plates, 4 discs and flange from the transmission case.

67. INSPECT BRAKE DISC NO. 4
68. REMOVE REAR PLANETARY GEAR ASSEMBLY

a. Remove the rear planetary gear assembly from the transmission case.

b. Remove the 2 thrust needle roller bearings from the rear planetary gear assembly.

c. Remove the thrust bearing race No.9 from the transmission case.

69. INSPECT REAR PLANETARY GEAR ASSEMBLY

70. REMOVE 1ST AND REVERSE BRAKE RETURN SPRING SUB-ASSEMBLY
a. Place SST on the 1st and reverse brake return spring sub-assembly and compress the brake return spring.
SST 09350-30020 (09350-07050)
b. Using SST, remove the snap ring and the brake return spring.
SST 09350-30020 (09350-07070)

71. INSPECT 1ST AND REVERSE BRAKE RETURN SPRING SUB-ASSEMBLY

72. REMOVE 1ST AND REVERSE BRAKE PISTON
a. Hold the 1st and reverse brake piston and blow compressed air (392 kPa, 4 kgf/cm2, 57 psi) into the transmission case to remove the brake piston.

HINT:
If the piston does not pop out with compressed air, lift the piston out with needle-nose pliers.

b. Remove the brake apply tube from the piston.
c. Remove the O-ring from brake piston.

73. REMOVE BRAKE REACTION SLEEVE
a. Using SST, remove the reaction sleeve.
SST 09350-30020 (09350-07080)
b. Remove the 2 O-rings from the reaction sleeve.

74. REMOVE BRAKE PISTON NO. 4
a. Using SST, remove the brake piston No. 4.
SST 09350-30020 (09350-07080)
b. Remove the 2 O-rings from the brake piston No. 4.