Part 1

A960E AUTOMATIC TRANSMISSION: 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 (0.04 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 the 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.

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 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. FIX 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.

(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.

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) Pull the transmission wire out of the transmission case.

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

15. REMOVE TRANSMISSION VALVE BODY ASSEMBLY

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

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.

(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.

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.

(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, 2 thrust needle roller bearings and bearing race.

30. INSPECT NO. 2 ONE WAY CLUTCH ASSEMBLY Transmission Unit

31. REMOVE NO. 2 ONE WAY CLUTCH ASSEMBLY

(a) Remove the No. 2 one way clutch assembly and clutch drum thrust washer from the clutch drum and input shaft.

32. REMOVE NO. 3 BRAKE SNAP RING

(a) Using a screwdriver, remove the No. 3 brake snap ring from the transmission case.

33. REMOVE 2ND BRAKE DISC SET

(a) Remove the flange, 3 discs and 3 plates from the transmission case.

34. INSPECT 2ND BRAKE DISC SET Transmission Unit

35. REMOVE 2ND BRAKE PISTON HOLE SNAP RING

(a) Using SST, remove the snap ring.

SST : 09350-30020

09350-07060

36. REMOVE ONE WAY CLUTCH ASSEMBLY

(a) Remove the one way clutch assembly and the No. 1 planetary carrier thrust washer from the transmission case.

37. REMOVE 2ND BRAKE CYLINDER

(a) Remove the 2nd brake cylinder from the transmission case.

38. REMOVE FRONT PLANETARY GEAR ASSEMBLY

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

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

39. INSPECT FRONT PLANETARY GEAR ASSEMBLY Transmission Unit

40. INSPECT ONE WAY CLUTCH ASSEMBLY Transmission Unit

41. REMOVE FRONT PLANETARY RING GEAR

(a) Remove the front planetary ring gear from the transmission case.

42. REMOVE CENTER PLANETARY RING GEAR

(a) Using a screwdriver, remove the snap ring.

(b) Remove the center planetary ring gear from the front planetary ring gear.

(c) Using a screwdriver, remove the snap ring.

(d) Remove the center planetary ring gear flange from the center planetary ring gear.

(e) Remove the thrust needle roller bearing from the front planetary ring gear flange.

43. REMOVE NO. 1 BRAKE DISC

(a) Remove the flange, the 3 discs and the 3 plates from the transmission case.

44. INSPECT NO. 1 BRAKE DISC Transmission Unit

45. REMOVE BRAKE PISTON RETURN SPRING SNAP RING

(a) Using a screwdriver, remove the brake piston return spring snap ring from the transmission case.

46. REMOVE BRAKE PISTON RETURN SPRING SUB-ASSEMBLY

(a) Remove the brake piston return spring, the No. 1 brake piston and the No. 1 brake cylinder from the transmission case.

47. INSPECT BRAKE PISTON RETURN SPRING SUB-ASSEMBLY Transmission Unit

48. REMOVE NO. 1 BRAKE PISTON

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

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 No. 1 brake piston.