Disassembly

Precautions when disassembling and re-assembling transmissions

Because automatic transmissions consist of precision parts, pay attention to the following during assembly and disassembly.
● Carry out disassembly in a clean, dust-free location.
● Place a rubber mat on the bench; be careful not to scratch the parts.
● Do not use gloves or wastes. (Use nylon cloth or paper towels.)
● When disassembling the case connecting section, do not force anything with a screwdriver or similar tool; gently knock the
parts of the case with a rubber-headed hammer to remove them.
● Before disassembling, clean the external of the transmission. (To prevent any contamination from entering the transmission)
● Clean the disassembled parts with AT fluid or kerosene, and check the oil passages by blowing air.
(Be careful not to allow the AT fluid or kerosene to splash or spill.) Clean the disk, brake band, resin washer and rubber parts
using the AT fluid.
● Replace the gasket, oil seal, and the "O" and "D" rings with new ones.
● Apply the AT fluid to the sliding and rotating sections before re-assembly.
● Use new disc and brake band after soaking them in AT fluid for more than two hours.
● Do not use the oils other than those specified.
Inspections and measures
Item Points to be inspected Measure
Scratches and burrs
Replace parts
Clogged oil passages
Inspections of casting parts Put wire through or blow air to clean
and machining parts Remove the gasket
Remainings of gasket
Replace parts
Cracked parts
Those that do not turn smoothly Replace
Inspection of bearings
Streaks, pitching, scratches, cracks Replace
Inspection of bush and thrust
Scratches, burrs, wears, scorch Replace
washer
Scratches and hardened material on seal ring Replace
Inspection of oil seal and
Peripheral and lateral wear of seal ring Replace
gasket
Piston seal ring, oil seal, gasket Replace
Scratches or burrs Replace
Inspection of gear
Teeth worn considerably Replace
Inspection of spline Burrs, scratches, deformation Replace
Wear, scratches, deformation
Inspection of snap ring Replace
Parts with no interference
Inspection of screws Burrs, damaged parts Replace
Inspection of spring Settling, scorching Replace
Inspection of clutch disk and Wear, scorching, plate warp, crack, distortion, damaged
Replace
brake disk claw
Inspection of clutch plate and
Wear, scorch, distortion, damaged claw Replace
brake plate
Inspection of seal face (Face Scratches, dry spots, wear Replace
where the lip touches) Clogged with foreign matter Repair

Inspection procedure
When carrying out maintenance of the automatic transmission, check the transmission in the vehicle first to find the root of the
problem, and then determine whether the transmission should be disassembled or not.
Disassembling the transmission without finding the root of the problem will result in wasted time and may cause secondary
problems.

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Automatic transmission problems are categorized as follows:
1. Improper inspection or adjustment
2. Poor engine performance
3. Failure of hydraulic control mechanism
4. Failure of electric control unit
5. Mechanical failure in transmission
In order to properly diagnose the problem in the vehicle, try to determine as accurately as possible from the customer the nature
of the problem. Try to reproduce the problem if possible.

Nuts and bolts

Metric thread
Vehicle dimensions are generally specified in metric units. Metric threads are used for most of the parts. These are almost the
same size as inch threads. Therefore, when replacing screws, be sure to use screws of proper nominal diameter, pitch and
strength.
Identification of screw strength
Generally, the strength of metric threads is categorized as "4T" and "7T". This can be identified by the mark curved on the bolt
head. "T" indicates the tensile strength.
When replacing metric threads, use the screws of the specified strength or stronger (that is, with the same strength number or
larger). It is also important to use the proper size screws.
The general sizes and pitches (not including exceptions) are as shown in the table.
Metric coarse screw thread
Nominal Nominal
Pitch [mm(in.)] Pitch [mm(in.)]
diameter diameter
M1.6 0.35(0.0138) M12 1.75(0.0689)
M2 0.4(0.0157) M14 2(0.0787)
M2.2 0.45(0.0177) M16 2(0.0787)
M2.5 0.45(0.0177) M18 2.5(0.0984)
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 M3X0.5 0.5(0.0197) M20 2.5(0.0984)
M3.5 0.6(0.0236) M22 2.5(0.0984)
M4X0.7 0.7(0.0276) M24 3(0.1181)
M4.5 0.75(0.0295) M27 3(0.1181)
M5X0.8 0.8(0.0314) M30 3.5(0.1378)
M6 1(0.0394) M33 3.5(0.1378)
M7 1(0.0394) M36 4(0.1574)
M8 1.25(0.0492) M39 4(0.1574)
M10 1.5(0.0591)

Metric coarse screw thread

Nominal Nominal
Pitch [mm(in.)] Pitch [mm(in.)]
diameter diameter
M8X1 1(0.0394) M22X1.5 1.5(0.0590)
M10X1.25 1.25(0.0492) M24X2 2(0.0787)
M12X1.25 1.25(0.0492) M27X2 2(0.0787)
M14X1.5 1.5(0.0590) M30X2 2(0.0787)
M16X1.5 1.5(0.0590) M33X2 2(0.0787)
M18X1.5 1.5(0.0590) M36X2 2(0.0787)
M20X1.5 1.5(0.0590) M39X2 2(0.0787)

Standard tightening torque

Tighten the nuts and bolts with the specified torque (tolerance: ±10%). When the torque is not specified, refer to the table below.
When the bolts and nuts are replaced with new ones of higher strength than original, the tightening torque should be the same as
that of the original nuts and bolts.

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Unit system
SI units (International units) are generally used in this manual.
SI units are indicated in the table below without brackets { }. Conventional units are indicated in brackets.
Quantity Unit Quantity Unit Quantity Unit
Length m Temperature °C(°F) Torque N·m{kgf·m, lbf·ft}
Mass (weight) kg Plane angle °,'," Force N {kgf}
Time s Area m² Pressure Pa {kgf/cm²}
Negative
Pa {mmhg} Current A Volume cm³ {cc, L}
pressure
Quantity of
Voltage V Speed km/h(mph) A·h
electricity
Resistance Ω Revolution rpm Spring constant N/mm {kgf/mm}

Symbol

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The symbols shown below are used in the manual.

Terms
Term Description
Standard values Indicates the inspection and adjustment tolerance values.
Limit values Indicates the maximum and minimum inspection and adjustment values.
Caution Indicates operations which require special caution, and prohibited operations.
Special tools Indicates the part numbers of special tools to be used for operation.
Indicates the center value of the specified tightening torque. Carry out tightening within ±
Tightening torque
10% of the specified value.

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