Disassembly [10/2023 - ]: Procedure
- SECURE AUTOMATIC TRANSMISSION ASSEMBLY
- REMOVE TCM
- REMOVE BREATHER PLUG SUB-ASSEMBLY
- REMOVE TRANSMISSION OIL THERMOSTAT
- REMOVE PARK/NEUTRAL POSITION SWITCH ASSEMBLY NOTE:
- When reusing the park/neutral position switch assembly, try not to remove the park/neutral position switch assembly.
- When removing the parts related to the parking lock, remove the park/neutral position switch assembly.
- When reusing the park/neutral position switch assembly, put matchmarks on the park/neutral position switch assembly and automatic transmission case sub-assembly.
*a Matchmark - - - When reusing the park/neutral position switch assembly, put matchmarks on the park/neutral position switch assembly and automatic transmission case sub-assembly.
- Remove the nut, spring washer and transmission control shaft lever RH.
- Using a screwdriver, pry out the lock washer.NOTE:
Be careful not to damage the park/neutral position switch assembly.
HINT:
Tape the screwdriver tip before use.
- Remove the nut and lock washer.
- Remove the bolt and park/neutral position switch assembly from the automatic transmission case sub-assembly.
HINT:
Make sure that the manual valve lever shaft has not been rotated prior to installing the park/neutral position switch assembly as the detent spring may become detached from the manual valve lever shaft.
- REMOVE AUTOMATIC TRANSMISSION OIL PAN SUB-ASSEMBLY
*1 Overflow Plug *2 No. 1 Transmission Oil Filler Tube *3 Gasket - - - Remove the refill plug and gasket from the automatic transmission case sub-assembly.
- Using a 6 mm hexagon socket wrench, remove the overflow plug and gasket from the automatic transmission assembly.
- Using a 6 mm hexagon socket wrench, remove the No. 1 transmission oil filler tube from the automatic transmission assembly.
- Remove the 13 bolts, automatic transmission oil pan sub-assembly and automatic transmission oil pan gasket from the automatic transmission case sub-assembly.
- Remove the 4 transmission oil cleaner magnets from the automatic transmission oil pan sub-assembly.
- Examine the particles in the automatic transmission oil pan sub-assembly.
- Use the removed transmission oil cleaner magnets to collect any steel chips.
Examine the chips and particles in the automatic transmission oil pan sub-assembly and on the transmission oil cleaner magnets to determine what type of wear might be found in the automatic transmission assembly.
Result
Steel (magnetic)
Bearing, gear and clutch plate wear
Brass (non-magnetic)
Bushing wear
- Use the removed transmission oil cleaner magnets to collect any steel chips.
- REMOVE VALVE BODY OIL STRAINER ASSEMBLY
Refer to PROCEDURE - Step 9
- REMOVE NO. 2 TRANSMISSION OIL PIPE (w/ Stop And Start System)
- REMOVE NO. 3 TRANSMISSION OIL PIPE (w/ Stop And Start System)
- REMOVE OIL PUMP WITH MOTOR ASSEMBLY (w/ Stop And Start System)
- REMOVE TRANSMISSION VALVE BODY ASSEMBLY
Refer to PROCEDURE - Step 13 - REMOVE TRANSMISSION REVOLUTION SENSOR (SP2)
Refer to PROCEDURE - Step 2
- REMOVE TRANSMISSION REVOLUTION SENSOR (NT)
Refer to PROCEDURE - Step 3
- REMOVE TRANSMISSION WIRE
Refer to PROCEDURE - Step 4 - REMOVE TRANSMISSION OIL PIPE
- REMOVE PARKING LOCK PAWL BRACKET
- REMOVE PARKING LOCK ROD SUB-ASSEMBLY
- REMOVE PARKING LOCK PAWL SHAFT
- REMOVE MANUAL VALVE LEVER SUB-ASSEMBLY
- Using a screwdriver and a hammer, cut off the spacer and remove it from the manual valve lever shaft.NOTE:
Be careful not to damage the manual valve lever shaft.
HINT:
Tape the screwdriver tip before use.
- Using a 3 mm pin punch and hammer, remove the spring pin from the manual valve lever shaft.
HINT:
Slowly tap out the spring pin so that it does not fall into the automatic transmission case sub-assembly.
- Remove the manual valve lever shaft and manual valve lever sub-assembly from the automatic transmission case sub-assembly.
- Using a screwdriver and a hammer, cut off the spacer and remove it from the manual valve lever shaft.
- REMOVE NO. 2 FRONT OIL PUMP COVER SUB-ASSEMBLY
SST bolt installation position - - - Remove the 11 bolts from the No. 2 front oil pump cover sub-assembly.
- Temporarily install the 2 bolts to the position shown in the illustration and remove the No. 2 front oil pump cover sub-assembly.
HINT:
Use an M10 x 1.25 bolt.
- If the No. 2 front oil pump cover sub-assembly is stuck and cannot be detached:
Using SST, rotate and remove the No. 2 front oil pump cover sub-assembly by hand as shown in the illustration.
- SST: 09380-60012
- 09381-06010
- 09381-06050
- 09381-06120
- SST: 09950-50013
- 09955-05010
- SST: 09322-35010
- 09322-03030
- SST: 09380-60012
- Remove the O-ring from the No. 2 front oil pump cover sub-assembly.
- Remove the gear thrust washer from the No. 2 front oil pump cover sub-assembly.
- REMOVE DRIVE SPROCKET AND TRANSMISSION DRIVE CHAIN
- REMOVE OIL PUMP ASSEMBLY WITH DRIVEN SPROCKET
- INSPECT TRANSMISSION DRIVE CHAIN
See step 1 - INSPECT DRIVE SPROCKET
See step 2 - REMOVE STATOR SHAFT ASSEMBLY
*1 Stator Shaft Assembly *2 Thrust Bearing Race *3 Thrust Needle Roller Bearing - - - Using a T50 "TORX" socket wrench, remove the 2 screws.
- Remove the stator shaft assembly, thrust bearing race and thrust needle roller bearing from the automatic transmission case sub-assembly.
- Remove the oil seal ring from the stator shaft assembly.
- INSPECT STATOR SHAFT ASSEMBLY
See step 3 - REMOVE NO. 1 BRAKE FLANGE
- REMOVE 1ST AND REVERSE BRAKE PLATE STOPPER SPRING
*a End of brake plate stopper spring - - Pull lightly on the end Remove in the direction of the arrow - Remove the 1st and reverse brake plate stopper spring.
- Pull lightly on the end of the 1st and reverse brake plate stopper spring.
- Remove the 1st and reverse brake plate stopper spring from the front support sub-assembly in the direction indicated by the arrow.
- Remove the 1st and reverse brake plate stopper spring.
- REMOVE NO. 1 BRAKE DISC
- INSPECT NO. 1 BRAKE DISC
See step 4 - REMOVE BRAKE PISTON RETURN SPRING SUB-ASSEMBLY (NO. 1 BRAKE)
- INSPECT BRAKE PISTON RETURN SPRING SUB-ASSEMBLY (NO. 1 BRAKE)
See step 5 - REMOVE NO. 1 BRAKE PISTON
*A Front Side *B Rear Side *1 No. 1 Brake Piston - - *a Cover the oil hole *b Blow air into the oil hole - While holding the No. 1 brake piston, apply compressed air to the oil hole of the front support sub-assembly to remove the No. 1 brake piston from the front support sub-assembly.
- Remove the 2 O-rings from the front No. 1 brake piston.
- REMOVE FRONT PLANETARY GEAR ASSEMBLY
- REMOVE PLANETARY SUN GEAR ASSEMBLY
*1 Planetary Sun Gear Assembly *2 Front Planetary Gear Assembly *3 Thrust Bearing Race *4 Thrust Needle Roller Bearing Expand the opening of the bearing Remove in this direction - Remove the planetary sun gear assembly, thrust bearing race and thrust needle roller bearing from the front planetary gear assembly.
- Remove the 11 oil seal rings from the front planetary gear assembly.
- Remove the 4 needle roller bearings from the front planetary gear assembly as shown in the illustration.
- INSPECT FRONT PLANETARY GEAR ASSEMBLY
See step 8 - REMOVE FRONT PLANETARY SUN GEAR SUB-ASSEMBLY
- INSPECT FRONT PLANETARY SUN GEAR SUB-ASSEMBLY
See step 7 - REMOVE FRONT PLANETARY OIL RECEIVER
- REMOVE FRONT PLANETARY RING GEAR WITH C-1 CLUTCH ASSEMBLY
- REMOVE FRONT PLANETARY RING GEAR
*1 Front Planetary Ring Gear *2 C-1 Clutch Assembly with C-2 Drum Sub-assembly - Using a screwdriver, remove the snap ring from the front planetary ring gear with C-1 clutch assembly.NOTE:
Be careful not to damage the front planetary ring gear with C-1 clutch assembly.
HINT:
Tape the screwdriver tip before use.
- Remove the front planetary ring gear from the C-1 clutch assembly with C-2 drum sub-assembly.
- Using a screwdriver, remove the snap ring from the front planetary ring gear with C-1 clutch assembly.
- REMOVE C-2 DRUM SUB-ASSEMBLY NOTE:
Do not disassemble the C-1 clutch assembly.
If disassembled, replace the C-1 clutch assembly with a new one.
- INSPECT C-1 CLUTCH ASSEMBLY
See step 11 - REMOVE C-2 CLUTCH ASSEMBLY
- REMOVE C-3 CLUTCH ASSEMBLY
- REMOVE NO. 2 BRAKE DISC
*1 No. 2 Brake Disc *2 No. 2 Brake Plate *3 No. 2 Brake Flange - - - Using a screwdriver, remove the snap ring from the automatic transmission case sub-assembly.NOTE:
Be careful not to damage the automatic transmission case sub-assembly.
HINT:
Tape the screwdriver tip before use.
- Remove the 5 No. 2 brake plates, 5 No. 2 brake discs and No. 2 brake flange from the automatic transmission case sub-assembly.
- Using a screwdriver, remove the snap ring from the automatic transmission case sub-assembly.
- INSPECT NO. 2 BRAKE DISC
See step 12 - REMOVE NO. 2 BRAKE PISTON
- Set SST on the brake piston return spring sub-assembly (No. 2 brake), automatic transmission case sub-assembly and tighten SST to compress the brake piston return spring sub-assembly (No. 2 brake).
- SST: 09308-14010
- SST: 09380-60012
- 09381-06010
- 09381-06020
- 09381-06040
- 09381-06050
- 09381-06090
- 09381-06120
- 09381-06140
- Using snap ring expander, remove the hole snap ring from the center support assembly.
- Remove the brake piston return spring sub-assembly (No. 2 brake) from the No. 2 brake piston.
- While holding the automatic transmission case sub-assembly, apply compressed air (400 kPa (4.1 kgf/cm2
, 58 psi)) to the oil hole to the No. 2 brake piston to lift it from the center support assembly.
HINT:
While evenly and lightly pressing on the No. 2 brake piston using your hand, blow in air a little at a time to remove the No. 2 brake piston smoothly.
- Using 2 needle-nose pliers, remove the No. 2 brake piston from the center support assembly.NOTE:
Be careful not to damage the No. 2 brake piston.
HINT:
Tape the tip of needle-nose pliers before use.
- Remove the O-ring from the No. 2 brake piston.
- Set SST on the brake piston return spring sub-assembly (No. 2 brake), automatic transmission case sub-assembly and tighten SST to compress the brake piston return spring sub-assembly (No. 2 brake).
- INSPECT BRAKE PISTON RETURN SPRING SUB-ASSEMBLY (NO. 2 BRAKE)
See step 13 - REMOVE CENTER SUPPORT ASSEMBLY WITH 1ST AND REVERSE BRAKE PISTON
- REMOVE 1ST AND REVERSE BRAKE PISTON
*1 1st and Reverse Brake Piston - - *a Oil Hole - - - While holding the center support assembly, apply compressed air (400 kPa (4.1 kgf/cm2
, 58 psi) to the oil hole to remove the 1st and reverse brake piston from the center support assembly.
HINT:
While evenly and lightly pressing on the 1st and reverse brake piston using your hand, blow in air a little at a time to remove the 1st and reverse brake piston.
- Remove the 2 O-rings from the 1st and reverse brake piston.
- Remove the O-ring from the center support assembly.
- While holding the center support assembly, apply compressed air (400 kPa (4.1 kgf/cm2
, 58 psi) to the oil hole to remove the 1st and reverse brake piston from the center support assembly.
- REMOVE CENTER PLANETARY RING GEAR WITH CENTER PLANETARY RING GEAR FLANGE
- REMOVE CENTER PLANETARY RING GEAR FLANGE
*1 Center Planetary Ring Gear Flange *2 Center Planetary Ring Gear - Using a screwdriver, remove the snap ring from the center planetary ring gear.NOTE:
Be careful not to damage the center planetary ring gear.
HINT:
Tape the screwdriver tip before use.
- Remove the center planetary ring gear flange from the center planetary ring gear.
- Using a screwdriver, remove the snap ring from the center planetary ring gear.
- REMOVE REAR PLANETARY RING GEAR WITH REAR PLANETARY RING GEAR FLANGE
*1 Rear Planetary Ring Gear with Rear Planetary Ring Gear Flange *2 Rear Multiple Disc Clutch Assembly *3 Thrust Needle Roller Bearing *4 Thrust Bearing Race - Remove the rear planetary gear assembly with planetary sun gear sub-assembly and center planetary gear assembly and rear multiple disc clutch assembly, thrust bearing race and thrust needle roller bearing from the automatic transmission case sub-assembly.
- Using SST, remove the rear planetary ring gear with rear planetary ring gear flange, rear multiple disc clutch assembly, 2 thrust needle roller bearings and 2 thrust bearing races from the rear planetary gear assembly with planetary sun gear sub-assembly and center planetary gear assembly.
- SST: 09950-40011
- 09951-04010
- 09954-04020
- 09955-04041
- 09957-04010
- 09952-04010
- 09953-04020
- SST: 09950-60011
- 09951-00250
- SST: 09950-40011
- REMOVE REAR PLANETARY RING GEAR FLANGE
*1 Rear Planetary Ring Gear Flange *2 Rear Planetary Ring Gear - Using a screwdriver, remove the snap ring from the rear planetary ring gear.NOTE:
Be careful not to damage the rear planetary ring gear.
HINT:
Tape the screwdriver tip before use.
- Remove the rear planetary ring gear flange from the rear planetary ring gear.
- Using a screwdriver, remove the snap ring from the rear planetary ring gear.
- REMOVE CENTER PLANETARY GEAR ASSEMBLY
- INSPECT CENTER PLANETARY GEAR ASSEMBLY
See step 16 - REMOVE PLANETARY SUN GEAR SUB-ASSEMBLY
- INSPECT PLANETARY SUN GEAR SUB-ASSEMBLY
See step 17 - INSPECT REAR PLANETARY GEAR ASSEMBLY
See step 18 - REMOVE NO. 4 CLUTCH DISC
*1 No. 4 Clutch Plate *2 No. 4 Clutch Disc *3 Clutch Flange - - - Using a screwdriver, remove the snap ring from the output shaft assembly.NOTE:
Be careful not to damage the output shaft assembly.
HINT:
Tape the screwdriver tip before use.
- Remove the 5 No. 4 clutch plates, 5 No. 4 clutch discs and clutch flange from the output shaft assembly.
- Using a screwdriver, remove the snap ring from the output shaft assembly.
- INSPECT NO. 4 CLUTCH DISC
See step 19 - REMOVE C-4 CLUTCH PISTON
*1 C-4 Clutch Balancer *2 Forward Clutch Return Spring Sub-assembly (C-4 clutch) *3 C-4 Clutch Piston - - *a Oil Hole - - - Set SST on the C-4 clutch balancer and compress the forward clutch return spring sub-assembly (C-4 clutch) using a press.
- SST: 09387-00020
- Using SST, remove the snap ring from the output shaft assembly.
- SST: 09350-30020
- 09350-07070
- SST: 09350-30020
- Remove the C-4 clutch balancer and forward clutch return spring sub-assembly (C-4 clutch) from the output shaft assembly.
- Remove the 2 O-rings from the C-4 clutch balancer.
- While holding the output shaft assembly, apply compressed air (400 kPa (4.1 kgf/cm2 , 58 psi)) to the oil hole to remove the C-4 clutch piston from the output shaft assembly.
- Remove the O-ring from the C-4 clutch piston.
- Remove the O-ring from the output shaft assembly.
- Remove the 3 clutch drum oil seal rings from the output shaft assembly.
- Set SST on the C-4 clutch balancer and compress the forward clutch return spring sub-assembly (C-4 clutch) using a press.
- INSPECT FORWARD CLUTCH RETURN SPRING SUB-ASSEMBLY (C-4 CLUTCH)
See step 20 - REMOVE BRAKE PLATE STOPPER SPRING
*a End of brake plate stopper spring - - Pull lightly on the end Remove in the direction of the arrow - Remove the brake plate stopper spring.
- Pull lightly on the end of the brake plate stopper spring.
- Remove the brake plate stopper spring from the automatic transmission case sub-assembly in the direction indicated by the arrow.
- Remove the brake plate stopper spring.
- REMOVE TRANSMISSION CASE OIL SEAL
- REMOVE BALL BEARING
*a Hold - - Turn - - - for Inside:
1. Using SST, remove the ball bearing from the automatic transmission case sub-assembly.
- SST: 09950-40011
- 09951-04020
- 09952-04010
- 09953-04030
- 09955-04031
- 09957-04010
- 09954-04010
- SST: 09950-60011
- 09951-00650
- SST: 09950-40011
- for Outside:
1. Using SST, remove the snap ring from the automatic transmission case sub-assembly.
- SST: 09350-30020
- 09350-07060
2. Using SST, remove the ball bearing from the automatic transmission case sub-assembly.
- SST: 09612-65014
- 09612-01060
- SST: 09350-30020
- for Inside:
- REMOVE AUTOMATIC TRANSMISSION CASE PLUG
HINT:
If automatic transmission fluid leaks from an automatic transmission case plug or the plug is corroded, replace it.
for T55 "TORX" for 12 mm head for 24 mm head - - - for T55 "TORX":
1. Using a T55 "TORX" socket wrench, remove the 2 automatic transmission case plugs and 2 O-rings from the automatic transmission case sub-assembly.
- for 12 mm head:
1. Remove the 13 automatic transmission case plugs and 13 O-rings from the automatic transmission case sub-assembly.
- for 24 mm head:
1. Remove the 2 automatic transmission case plugs and 2 O-rings from the automatic transmission case sub-assembly.
- for T55 "TORX":
- INSPECT AUTOMATIC TRANSMISSION CASE SUB-ASSEMBLY
See step 23