Transmission Assembly: Disassembly

CAUTION:

Never disassemble parts behind drum support. Refer to CROSS-SECTIONAL VIEW .

Drain ATF through drain plug.
Remove torque converter by holding it firmly and turning while pulling straight out.

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Remove tightening bolts ( ) for converter housing and transmission case.

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Remove converter housing from transmission case.
CAUTION:
Be careful not to scratch converter housing.
Remove O-ring from input clutch assembly.

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Remove tightening bolts ( ) for oil pump assembly and transmission case.

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Attach the sliding hammers [SST: ST25850000 (J-25721-A)] (A) to oil pump assembly and extract it evenly from transmission case.

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: Sliding hammer attachment position
CAUTION:
- Fully tighten the sliding hammer screws.
- Make sure that bearing race is installed to the oil pump assembly edge surface.
Remove O-ring from oil pump assembly.

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Remove bearing race from oil pump assembly.

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Remove seal ring from oil pump assembly.

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Remove under drive sun gear from under drive carrier assembly.

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Remove needle bearing from under drive sun gear.

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Remove needle bearing from under drive carrier assembly.

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Remove front brake component part (retaining plates, drive plates and driven plate) from transmission case by using a wire (A) with its tip bent like a hook.

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Remove snap ring from transmission case using a flat-bladed screwdriver.

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CAUTION:
- Be careful not to scratch transmission case and 1st one-way clutch.
- Be careful not to damage snap ring.
Remove input clutch assembly (with 1st one-way clutch, under drive carrier assembly, front brake hub, front carrier assembly, and rear internal gear) from transmission case.

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Remove 1st one-way clutch from front brake hub.

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Remove under drive carrier assembly (with front brake hub) from front carrier assembly.

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Remove needle bearing from front carrier assembly.

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Remove seal rings from input clutch assembly.

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Remove mid carrier assembly and rear carrier assembly as a unit.

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Remove mid carrier assembly from rear carrier assembly.

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Remove needle bearing (front side) from mid carrier assembly.

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Remove needle bearing (rear side) from mid carrier assembly.

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Remove bearing race from rear carrier assembly.

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Remove needle bearing from rear carrier assembly.

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Remove mid sun gear assembly, rear sun gear assembly, and high and low reverse clutch hub as a unit.

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CAUTION:
Be careful to remove then with bearing race and needle bearing.
Remove high and low reverse clutch assembly from direct clutch assembly.

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CAUTION:
Make sure that needle bearing is installed to the high and low reverse clutch assembly edge surface.
Remove direct clutch assembly from reverse brake.

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Remove needle bearing from drum support.

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Remove snap ring from joint connector .

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Push joint connector .

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CAUTION:
Be careful not to damage connector.
Remove oil pan mounting bolts ( ).

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: Front
Remove oil pan and oil pan gasket.
Remove magnets from oil pan.

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Disconnect output speed sensor connector .

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CAUTION:
Be careful not to damage connector.
Disengage terminal clips ( ).

Remove Control Valve & TCM mounting bolts and clip

from the Control Valve & TCM.

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: Front

Bolt Symbol	Length mm (in)	Number Of Bolts
	43 (1.69)	3
	40 (1.57)	2
	54 (2.13)	6
	50 (1.97)	2
*	50 (1.97)	1

*: Reamer bolt

Remove the Control Valve & TCM from transmission case.

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CAUTION:
When removing, never with the manual valve notch and manual plate height. Remove it vertically.
Remove joint connector from the Control Valve & TCM using a flat-bladed screwdriver .

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Disconnect TCM connector .

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CAUTION:
Be careful not to damage connector.

Remove rear extension assembly (2WD) or adapter case assembly (AWD) according to the following procedures.

2WD

Remove tightening bolts for rear extension assembly and transmission case.

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: Bolt

Tap rear extension assembly using a soft hammer.

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CAUTION:

Be careful not to damage rear extension.

Remove rear extension assembly from transmission case. (With needle bearing.)

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Remove bearing race from output shaft.

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Remove output shaft from transmission case by rotating left/right.

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Remove parking gear

from output shaft

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Remove seal rings

from output shaft.

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AWD

Remove tightening bolts for adapter case assembly and transmission case.

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	: Bracket
	: Bolt

Tap adapter case assembly using a soft hammer.

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CAUTION:

Be careful not to damage adapter case.

Remove adapter case assembly from transmission case. (With needle bearing)

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Remove bearing race from output shaft.

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Remove output shaft from transmission case by rotating left/right.

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Remove gasket from transmission case.

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Remove parking gear

from output shaft

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Remove seal rings

from output shaft.

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Remove needle bearing from transmission case.

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Remove output speed sensor from transmission case.

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: Bolt
CAUTION:
- Never subject it to impact by dropping or hitting it.
- Never disassemble.
- Never allow metal filings, etc. to get on the sensor's front edge magnetic area.
- Never place in an area affected by magnetism.
Remove reverse brake snap ring (fixing plate) with 2 flat-bladed screwdrivers.

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CAUTION:
- Be careful not to scratch transmission case and reverse brake retaining plate.
- Be careful not to damage snap ring.
NOTE:
Press out snap ring from the transmission case oil pan side gap with a flat-bladed screwdriver, and remove it using a another screwdriver.
Remove reverse brake retaining plate from transmission case.
Remove N-spring from transmission case.

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Remove reverse brake component part (drive plates, driven plates, and dish plates) from transmission case.

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Remove snap ring (fixing spring retainer) using a flat-bladed screwdriver.

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CAUTION:
- Be careful not to scratch transmission case and spring retainer.
- Be careful not to damage snap ring.
Remove reverse brake spring retainer and reverse brake return spring from transmission case.

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Remove seal rings from drum support.

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Remove needle bearing from drum support edge surface.

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Remove reverse brake piston from transmission case with compressed air. Refer to OIL CHANNEL .

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: Reverse brake pressure hole

CAUTION:
Care should be taken not to abruptly blow air. It makes pistons incline, as the result, it becomes hard to disassemble the pistons.
Remove D-rings from reverse brake piston.

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Remove manual shaft retaining pin with pair of nippers.

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CAUTION:
Be careful not to cut retaining pin.
Remove manual plate from detent spring .

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Remove parking rod from manual plate.
Install manual plate to detent spring.
Use a pin punch [4 mm (0.16 in) dia. commercial service tool] to knock out retaining pin .

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Remove manual plate from manual shaft.

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Remove manual shaft from transmission case.

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Remove manual shaft oil seals using a flat-bladed screwdriver.

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CAUTION:
Be careful not to scratch transmission case.
Remove detent spring from transmission case.

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: Bolt
Remove needle bearing from rear extension (2WD) or adapter case (AWD).

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Remove parking actuator support from rear extension (2WD) or adapter case (AWD).

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Remove parking pawl (with return spring) and pawl shaft from rear extension (2WD) or adapter case (AWD).

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Remove return spring from parking pawl .

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Remove rear oil seal from rear extension or adapter case using a flat-bladed screwdriver (A).

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: 2WD

: AWD

CAUTION:
Be careful not to scratch rear extension or adapter case.