Part 1

A960E AUTOMATIC TRANSMISSION / TRANSAXLE: AUTOMATIC TRANSMISSION UNIT: DISASSEMBLY

CAUTION:
When working with FIPG material, perform the following:

* Using a razor blade and gasket scraper, remove all the old FIPG material from the gasket surfaces.
* Thoroughly clean all components to remove any loose material.
* Clean both sealing surfaces with a non-residue solvent.
* Apply FIPG in a continuous line (width approximately 1 mm (0.0393 in.)) along the sealing surface.
* Parts must be assembled within 10 minutes of application. Otherwise, the FIPG material must be removed and reapplied.
1. REMOVE TRANSMISSION CASE COVER

(a) Remove the 2 bolts and the transmission case cover.

2. REMOVE TRANSMISSION CONTROL SHAFT LEVER RH

(a) Remove the nut, spring washer and transmission control shaft lever RH.

3. REMOVE PARK/NEUTRAL POSITION SWITCH ASSEMBLY

(a) Using a screwdriver, unstake the lock washer.

(b) Remove the nut and lock washer.

(c) Remove the bolt and park/neutral position switch.

4. REMOVE TRANSMISSION OIL COOLER

(a) Remove the 3 bolts and transmission oil cooler.

(b) Remove the 2 O-rings from the transmission oil cooler.

Text in Illustration

5. REMOVE TRANSMISSION REVOLUTION SENSOR

(a) Remove the 2 bolts and the 2 transmission revolution sensors.

(b) Remove the O-ring from each sensor.

6. REMOVE AUTOMATIC TRANSMISSION BREATHER TUBE

(a) Remove the 2 bolts.

(b) Remove the breather tube.

7. REMOVE AUTOMATIC TRANSMISSION HOUSING

(a) Remove the 10 bolts.

(b) Remove the transmission housing.

8. REMOVE EXTENSION HOUSING DUST DEFLECTOR

(a) Using a brass bar and a hammer, remove the extension housing dust deflector.

NOTICE:
Be careful not to damage the extension housing.

9. REMOVE EXTENSION (ATM) HOUSING SUB-ASSEMBLY

(a) Remove the 6 bolts.

(b) Using a screwdriver, remove the extension (ATM) housing sub-assembly.

(d) Remove the transmission case adaptor radial ball bearing.

(e) Using a snap ring expander, remove the snap ring.

(f) Remove the thrust needle roller bearing and the 2 thrust bearing races.

10. REMOVE AUTOMATIC TRANSMISSION EXTENSION HOUSING OIL SEAL

(a) Using a screwdriver, remove the oil seal.

11. SECURE AUTOMATIC TRANSMISSION CASE SUB-ASSEMBLY

(a) Install the transmission case on the overhaul attachment.

12. REMOVE AUTOMATIC TRANSMISSION OIL PAN SUB-ASSEMBLY

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

(a) Remove the overflow plug and the gasket.

(b) Remove the drain plug and the gasket.

(c) Remove the 20 bolts, oil pan and gasket.

(d) Examine particles in the pan.

Text in Illustration

(1) Remove the magnets from the oil pan and use them to collect any steel chips. Look carefully for the chips and particles in the pan and on the magnet to anticipate the type of wear which might be found in the transaxle.

Steel (magnetic): bearing, gear and plate wear

Brass (non-magnetic): bearing wear

13. REMOVE VALVE BODY OIL STRAINER ASSEMBLY

(a) Turn over the transmission.

(b) Remove the 4 bolts and valve body oil strainer assembly from the valve body.

(c) Remove the O-ring from the valve body oil strainer assembly.

Text in Illustration

14. REMOVE TRANSMISSION WIRE

(a) Remove the bolt and temperature sensor clamp, and separate the ATF temperature sensor.

(b) Remove the 2 bolts and disconnect the 2 clamps.

(d) Remove the bolt and pull out the transmission wire.

(e) Remove the O-ring from the transmission wire.

Text in Illustration

15. REMOVE TRANSMISSION VALVE BODY ASSEMBLY

(a) Remove the bolt, detent spring cover and detent spring.

(b) Remove the 19 bolts.

17. REMOVE BRAKE DRUM GASKET

(a) Remove the 3 brake drum gaskets.

18. REMOVE CHECK BALL BODY

(a) Remove the check ball body and the spring.

Text in Illustration

19. REMOVE C-2 ACCUMULATOR PISTON

(a) While blowing compressed air into the oil hole, remove the C-2 accumulator piston and the spring.

(b) Remove the 2 O-rings from the piston.

NOTICE:
Take care as the C-3 and B-3 accumulator pistons may jump out.

20. REMOVE B-3 ACCUMULATOR PISTON

(a) Applying compressed air to the oil hole, remove the B-3 accumulator piston and the spring.

(b) Remove the 2 O-rings from the piston.

NOTICE:
Take care as the C-3 accumulator piston may jump out.

21. REMOVE C-3 ACCUMULATOR PISTON

(a) While blowing compressed air into the oil hole, remove the C-3 accumulator piston and the 2 springs.

(b) Remove the 2 O-rings from the piston.

22. REMOVE B-1 ACCUMULATOR VALVE

(a) Remove the B-1 accumulator valve and the spring.

23. REMOVE PARKING LOCK PAWL BRACKET

(a) Remove the 3 bolts and the parking lock pawl bracket.

24. REMOVE PARKING LOCK ROD SUB-ASSEMBLY

(a) Disconnect the parking lock rod from the manual valve lever.

25. REMOVE PARKING LOCK PAWL SHAFT

(a) Pull out the parking lock pawl shaft from the front side, then remove the lock pawl and the spring.

Text in Illustration

(b) Remove the E-ring from the shaft.

26. 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 sub-assembly.

27. REMOVE MANUAL VALVE LEVER SHAFT OIL SEAL

(a) Using a screwdriver, remove the 2 oil seals.

28. REMOVE OIL PUMP ASSEMBLY

(a) Remove the 9 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 No. 1 thrust bearing race from the oil pump.

Text in Illustration

(d) Remove the O-ring from the oil pump.

29. 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 and thrust needle roller bearing.

Text in Illustration

30. SUPPORT CLUTCH DRUM AND INPUT SHAFT

(a) Place the oil pump onto the torque converter clutch, and then place the clutch drum and input shaft onto the oil pump.

Text in Illustration

31. REMOVE REVERSE CLUTCH HUB SUB-ASSEMBLY

(a) Using a screwdriver, remove the snap ring from the clutch drum and input shaft.

(b) Remove the reverse clutch hub sub-assembly with the reverse clutch reaction sleeve, the clutch cushion plate, the reverse clutch flange, the 4 No. 3 clutch discs, and the 3 No. 3 clutch plates from the forward clutch hub.

32. REMOVE REVERSE CLUTCH REACTION SLEEVE

(a) Remove the reverse clutch reaction sleeve from the reverse clutch hub sub-assembly.

33. REMOVE NO. 3 CLUTCH DISC

(a) Remove the clutch cushion plate, the reverse clutch flange, the 3 plates and the 4 discs from the reverse clutch hub.

34. INSPECT NO. 3 CLUTCH DISC Transmission Unit

35. INSPECT REVERSE CLUTCH HUB SUB-ASSEMBLY Transmission Unit

36. REMOVE CLUTCH HUB SUB-ASSEMBLY

(a) Remove the clutch hub sub-assembly and thrust washer from the reverse clutch drum sub-assembly.

(b) Remove the 2 thrust needle roller bearings and the thrust bearing race from the clutch hub sub-assembly.

37. INSPECT CLUTCH HUB SUB-ASSEMBLY Transmission Unit

38. REMOVE COAST CLUTCH HUB SUB-ASSEMBLY

(a) Remove the coast clutch hub sub-assembly from the reverse clutch drum sub-assembly.

39. INSPECT NO. 4 ONE-WAY CLUTCH ASSEMBLY Transmission Unit

40. REMOVE NO. 4 ONE-WAY CLUTCH ASSEMBLY

(a) Remove the No. 4 one-way clutch assembly and the clutch hub thrust washer from the coast clutch hub.