Disassembly
Warning. Because an automatic transmission is made up of a number of precision-manufactured parts, these parts must be handled with great care when designing and assembling. A rubber mat must be placed on the workbench, which must be kept clean at all times. During disassembly, do not use cloth gloves or rags. If necessary, use nylon products or paper napkins. All removed parts must be completely clean. The clutch disc, plastic and rubber parts should be cleaned with automatic transmission fluid, being careful not to leave dust, dirt, etc. on them.
1. Remove sand, dirt, etc. from the entire surface of the gearbox.
2. Place the gearbox on a workbench with the oil sump facing down.
3. Remove the torque converter.
4. Measuring input shaft end play before disassembly will usually determine if thrust washer replacement is required (except when major parts are replaced).
5. Remove pulse generators A and B.
6. Remove the manual control lever, then remove the transmission switch.
7. Remove the circlip and the positive downshift servo switch.
8. Remove the oil sump and its gasket.
9. Remove the oil filter from the valve body, controls.
10. Turn away a bolt of the gauge of temperature of oil. Push it out from the connector side.
11. Squeeze the tabs on the solenoid valve wiring harness o-ring and then push it into the housing.
12. Turn away bolts and remove the case of valves.
13. Remove the end sleeve.
14. Remove the termination shaft.
15. Turn away 14 bolts and remove the case of the hydrotransformer.
16. Turn away 6 bolts of fastening of the oil pump. Screw in special tools (09452-33100) into two removable holes in the oil pump housing.
Simultaneously and evenly rotate both pullers and remove the oil pump.
17. Remove spacer and differential.
18. Remove, moving up, the input shaft, then remove the front and rear couplings.
19. Remove the thrust bearing.
20. Remove the clutch hub.
21. Remove thrust washer and bearing.
22. Remove the positive downshift servo drum.
23. Using special tools (09222-28000, 09222-28100, 09456-21100), slide the servo inward and remove the circlip.
24. Remove the piston and servo spring.
25. Attach special tool (09453-21310) to the central support. Holding the handle of the tool, pull up the center support.
26. Remove the reverse and forward gears together.
27. Remove planet carrier and thrust bearing.
28. Remove wave spring, return spring, brake disc, brake plate, brake support plate.
29. Using a special tool (09454-21100), release the intermediate shaft. Remove it and 2 gear bearing parts.
30. Remove the internal gear, output flange, idler gear and bearing as a unit from the housing.
31. Remove the transmission shaft cover.
32. Turn away a lock nut.
Note. The lock nut has a left hand thread.
33. Knock out the transfer shaft towards the torque converter housing.
34. Using a special tool (09432-33200), remove the bearing from the transmission shaft.
35. Using special tools (09432-33800, 09433-21000), remove the bearing from the drive gear of the transmission shaft.
36. Using a special tool (09517-21400), remove the outer race of the transmission shaft bearing.
37. Turn away two bolts and remove a spacer core.
38. Turn away the lock screw and remove a shaft of manual control. Remove the steel ball, seat and spring.
Automatic transmission assembly
Warning. Do not reuse gaskets, seals and rubber parts, replace them with new ones. Do not use other greases. Apply automatic transmission fluid to all moving parts before installation.
Assembly is carried out in the reverse order of disassembly, using special tools and fixtures.
Dimensions of thrust bearings, rings and washers
Unit measurements: mm
Outside diameter | Int. diameter | Thickness | № |
70 | 55,7 | 1,4 | #1 |
70 | 55,7 | 1,8 | |
70 | 55,7 | 2,2 | |
70 | 55,7 | 2,6 | |
70 | 55,7 | 1,8 | #2 |
48,9 | 37 | 1,0 | #3 |
48,9 | 37 | 1,2 | |
48,9 | 37 | 1,4 | |
48,9 | 37 | 1,6 | |
48.9 | 37 | 1,8 | |
48,9 | 37 | 2,0 | |
48,9 | 37 | 2,2 | |
48,9 | 37 | 2,4 | |
48,1 | 34,4 | - | #4 |
40 | 21 | 2,4 | #5 |
42,6 | 28 | - | #6 |
54 | 38,7 | 1,6 | #7 |
52 | 36,4 | - | #8 |
41 | 28 | - | #9 |
39 | 28 | 1,2 | #10 |
38 | 22,2 | - | #11 |
52 | 36,4 | - | #12 |
58 | 44 | - | #13 |