Page 4177 of 4264
UNIT REPAIR (JR405E) 7A4-3
Disassembly steps
1. Torque converter
Pull the torque converter free.
NOTE:
Place a pan beneath the torque converter to catch
automatic transmission fluid (ATF) spillage.
Draining the ATF from the torque converter.
01ASSY101
2. Turbine sensor and speed sensor
Remove the turbine sensor from the transmission case.
02ASSY103
Remove the speed sensor from the transmission case.
03ASSY106
3. Inhibitor switch
Remove the 2 bolts and the inhibitor switch from the
transmission case.
240L300002
4. Oil pan
Lift and support the transmission with the holding fixture
and holding fixture base.
Holding fixture: 5-8841-0841-0
Holding fixture base: 5-8840-0003-0
Remove the drain plug from the oil pan and drain the
ATF from the oil pan.
Rotate the automatic transmission so that the converte
r
housing is facing up and drain the ATF.
Rotate the automatic transmission so that the oil pan is
facing up.
Remove the 19 bolts and the oil pan.
Page 4178 of 4264
7A4-4 UNIT REPAIR (JR405E)
04CV37
Inspect the bottom of the oil pan and strainer netting for
foreign material (clutch facing and metal shavings).
If there is an excessive accumulation of foreign material,
the oil strainer must be replaced.
Further inspection is required to determine the source o
f
the foreign material.
45CV29
5. Control valve assembly
Disconnect the 2 harness connectors leading to the
control valve.
Page 4179 of 4264
UNIT REPAIR (JR405E) 7A4-5
244L300001
Remove the 12 bolts and the control valve assembly.
Number of bolts Length
10 (A)
2 (B) 40 mm (1.57 in)
30 mm (1.18 in)
42ASSY118
NOTE:
Take care not to disturb the manual valve (inside the
control valve assembly).
Do not allow the pin to fall free (the pin prevents the valve
from turning).
Page 4180 of 4264
7A4-6 UNIT REPAIR (JR405E)
10ASSY116
6. Converter housing
Position the automatic transmission so that the
converter housing is facing up.
Remove the 8 bolts and the converter housing.
11ASSY068
7. O-ring
Remove the O-ring from the input shaft.
12ASSY067
8. Oil pump assembly and bearing race
Remove the 8 bolts.
Use a slide hammer to remove the oil pump assembly
from the transmission case.
NOTE:
To prevent damage to the oil pump bolt hole threads,
hand-tighten the slide hammer as far as possible.
Remove the bearing race from the oil pump assembly.
Inspect the bearing race surfaces for damage.
14ASSY057
9. Input shaft
Pull the input shaft free.
15ASSY049
10.Clutch pack (Reverse and high clutch assembly) and
bearing
Pull the clutch pack free.
Remove the bearing from the clutch pack.
Page 4181 of 4264
UNIT REPAIR (JR405E) 7A4-7
16ASSY047
11.High clutch hub, bearing, and bearing race
Remove the clutch hub, bearing (with bearing race),
and the bearing race.
Remove the bearing (with bearing race) and the bearing
race from the high clutch hub.
Inspect the bearing race surfaces for damage.
17ASSY040
12.Front sun gear, bearing, and bearing race
Remove the bearing, the front sun gear, and the bearing
race.
Remove the bearing and the bearing race from the fron
t
sun gear.
Inspect the bearing race surfaces for damage.
19ASSY113
13.2-4 brake retainer
Remove the brake seal ring and the sleeve.
23ASSY030
Attach the spring compressor to the transmission case.
Spring compressor: 5-8840-2764-0
24ASSY029
Force out the 2-4 brake retainer and remove the snap
ring.
NOTE:
Overturning the spring compressor will damage the 2-4
brake retainer.
Remove the spring compressor.
Page 4182 of 4264
7A4-8 UNIT REPAIR (JR405E)
25ASSY019
Remove the 2-4 brake retainer and return spring.
26ASSY026
14.Carrier assembly (Carrier and low clutch assembly),
bearing, bearing race, and 2 – 4 brake assembly
Pull the carrier assembly, the bearing, the bearing race
and the 2-4 brake assembly (Dish plate, retaining plate,
drive plate, and driven plate) from the transmission case
at the same time.
Remove the bearing, the bearing race, and the 2-4
brake assembly from the carrier assembly.
27U-SPG02
Remove the 3 brake springs from the transmission case.
28L&R06
15.Low and reverse brake
Remove the snap ring.
Pull the low and reverse brake free.
16.Rear extension (2WD) or Adapter case (4WD)
Rotate the transmission case so that the oil pan opening
is facing up.
Remove the 10 bolts and the rear extension (2WD) o
r
the adapter case (4WD).
Page 4183 of 4264
UNIT REPAIR (JR405E) 7A4-9
29ASSY091
17.Output shaft
Pull the output shaft from the transmission case.
30ASSY089
Remove the bearing (with bearing race) from the
transmission case.
31ASSY124
18.Parking pawl, shaft, spring, and spacer
Remove the parking pawl, shaft, spring and spacer from the
transmission case.
36ASSY075
19.Actuator support
Remove the actuator support from the transmission case.
37ASSY074
20.Low one-way clutch inner race and bearing
Loosen the 7 bolts securing the low one-way clutch inne
r
race.
NOTE:
Loosen the bolts a little at a time as uniformly as possible
to prevent the inner race from tilting and becoming
jammed.
Remove the 6 bolts. Support the low one-way clutch
inner race with your hand and remove the final bolt.
Page 4184 of 4264
7A4-10 UNIT REPAIR (JR405E)
39ASSY006
Remove the bearing and the low one-way clutch inner
race from the transmission case.
Remove the bearing from the low one-way clutch inne
r
race.
40ASSY005
21.Low and reverse brake return spring
Remove the low and reverse brake return spring from the
transmission case.
41L&R02
22.Low and reverse brake piston
Force compressed air (329kPa/4.0kg/cm
2) through the
transmission case oil passages.
42ASSY004
Remove the low and reverse brake piston from the
transmission case.