Page 369 of 4449
AT-292
DISASSEMBLY
Revision: 2004 November 2004 FX35/FX45
28. Remove oil pan and oil pan gasket.
29. Check foreign materials in oil pan to help determine causes of
malfunction. If the A/T fluid is very dark, smells burned, or con-
tains foreign particles, the frictional material (clutches, band)
may need replacement. A tacky film that will not wipe clean indi-
cates varnish build up. Varnish can cause valves, servo, and
clutches to stick and can inhibit pump pressure.
If frictional material is detected, perform A/T fluid cooler
cleaning. Refer to AT- 1 4 , "
A/T Fluid Cooler Cleaning" .
30. Remove magnets from oil pan.
31. Disconnect A/T fluid temperature sensor 2 connector.
CAUTION:
Be careful not to damage connector.
32. Straighten terminal clip to free A/T fluid temperature sensor 2
harness.
SCIA2308E
SCIA5199E
SCIA5200E
SCIA5023E
SCIA5146E
Page 370 of 4449
DISASSEMBLY
AT-293
D
E
F
G
H
I
J
K
L
MA
B
AT
Revision: 2004 November 2004 FX35/FX45
33. Disconnect revolution sensor connector.
CAUTION:
Be careful not to damage connector.
34. Straighten terminal clips to free revolution sensor harness.
35. Remove bolts A, B and C from control valve with TCM.
36. Remove control valve with TCM from transmission case.
CAUTION:
When removing, be careful with the manual valve notch and
manual plate height.Remove it vertically.
37. Remove A/T fluid temperature sensor 2 with bracket from con-
trol valve with TCM.
SCIA5024E
SCIA5293E
Bolt symbol Length mm (in) Number of bolts
A 42 (1.65) 5
B 55 (2.17) 6
C 40 (1.57) 1
SCIA5025E
SCIA5260E
SCIA5301E
Page 371 of 4449
AT-294
DISASSEMBLY
Revision: 2004 November 2004 FX35/FX45
38. Remove bracket from A/T fluid temperature sensor 2.
39. Remove O-ring from A/T assembly harness connector.
40. Remove rear extension assembly (2WD models) or adapter case assembly (AWD models) according to
the following procedures.
a.2WD models
i. Remove tightening bolts for rear extension assembly and trans-
mission case.
ii. Tap rear extension assembly with soft hammer.
SCIA5264E
SCIA5155E
SCIA3426E
SCIA5028E
Page 372 of 4449
DISASSEMBLY
AT-295
D
E
F
G
H
I
J
K
L
MA
B
AT
Revision: 2004 November 2004 FX35/FX45
iii. Remove rear extension assembly from transmission case. (With
needle bearing.)
b.AWD models
i. Remove tightening bolts for adapter case assembly and trans-
mission case. (With bracket)
ii. Tap adapter case assembly with soft hammer.
iii. Remove adapter case assembly from transmission case. (With
needle bearing)
SCIA5029E
SCIA5182E
SCIA5201E
SCIA5186E
Page 373 of 4449
AT-296
DISASSEMBLY
Revision: 2004 November 2004 FX35/FX45
iv. Remove gasket from transmission case.
41. Remove bearing race from output shaft.
42. Remove output shaft from transmission case by rotating left/
right.
43. Remove parking gear from output shaft.
44. Remove seal rings from output shaft.
SCIA5231E
SCIA5245E
SCIA5030E
SCIA5247E
SCIA5209E
Page 374 of 4449

DISASSEMBLY
AT-297
D
E
F
G
H
I
J
K
L
MA
B
AT
Revision: 2004 November 2004 FX35/FX45
45. Remove needle bearing from transmission case.
46. Remove revolution sensor from transmission case.
CAUTION:
Do not subject it to impact by dropping or hitting it.
Do not disassemble.
Do not allow metal filings, etc., to get on the sensor's
front edge magnetic area.
Do not place in an area affected by magnetism.
47. Remove reverse brake snap ring (fixing plate) using 2 flat-
bladed screwdrivers.
NOTE:
Press out snap ring from the transmission case oil pan side gap
using a flat-bladed screwdriver, and remove it using another
screwdriver.
48. Remove reverse brake retaining plate from transmission case.
Check facing for burns, cracks or damage. If necessary,
replace the plate.
49. Remove N-spring from transmission case.
50. Remove reverse brake drive plates, driven plates and dish plate
from transmission case.
Check facing for burns, cracks or damage. If necessary,
replace the plate.
SCIA5031E
SCIA2320E
SCIA5032E
SCIA5214E
SCIA2322E
Page 375 of 4449
AT-298
DISASSEMBLY
Revision: 2004 November 2004 FX35/FX45
51. Remove snap ring (fixing spring retainer) using a flat-bladed
screwdriver.
52. Remove spring retainer and return spring from transmission
case.
53. Remove seal rings from drum support.
54. Remove needle bearing from drum support edge surface.
SCIA2323E
SCIA2324E
SCIA3333E
SCIA2796E
Page 376 of 4449
DISASSEMBLY
AT-299
D
E
F
G
H
I
J
K
L
MA
B
AT
Revision: 2004 November 2004 FX35/FX45
55. Remove reverse brake piston from transmission case with com-
pressed air. Refer to AT- 2 8 2 , "
Oil Channel" .
CAUTION:
Care should be taken not to abruptly blow air. It makes pis-
tons incline, as the result, it becomes hard to disassemble
the pistons.
56. Remove lip seal and D-ring from reverse brake piston.
57. Use a pin punch (4mm dia. commercial service tool) to knock
out retaining pin.
58. Remove manual shaft retaining pin with nippers.
SCIA5047E
SCIA2795E
SCIA2328E
SCIA2329E