AUTOMATIC TRANSMISSION

C TRANSMISSION/TRANSAXLE

B
SECTION
AUTOMATIC TRANSMISSION AT

E
CONTENTS
PRECAUTIONS .......................................................... 2 REPAIR FOR COMPONENT PARTS ....................... 29 F
How to use this manual ............................................ 2 Oil Pump ................................................................. 29
Components ............................................................. 2 Front Sun Gear, 3rd One-way Clutch ..................... 32
Precautions .............................................................. 2 Front Carrier, Input Clutch, Rear Internal Gear ...... 34 G
PREPARATION ........................................................... 3 Mid Sun Gear, Rear Sun Gear, High and Low
Special Service Tools ............................................... 3 Reverse Clutch Hub ............................................... 39
Commercial Service Tools ........................................ 3 High and Low Reverse Clutch ................................ 44
H
A/T CONTROL SYSTEM ............................................ 4 Direct Clutch ........................................................... 46
Cross-Sectional View ............................................... 4 ASSEMBLY ............................................................... 48
Function of Clutch and Brake ................................... 4 Assembly (1) ........................................................... 48
OVERHAUL ................................................................ 5 Adjustment .............................................................. 60 I
Components ............................................................. 5 Assembly (2) ........................................................... 62
Oil Channel .............................................................11 SERVICE DATA AND SPECIFICATIONS (SDS) ...... 70
Locations of Adjusting Shims, Needle Bearings, Reverse Brake ........................................................ 70 J
Thrust Washers and Snap Rings ........................... 12 Total End Play ......................................................... 70
DISASSEMBLY ......................................................... 13
Disassembly ........................................................... 13
K

AT-1
 PRECAUTIONS

PRECAUTIONS PFP:00001

How to use this manual GCS00177

● This manual describes removal, installation, disassembly, assembly, inspection, and etc. of RE5R05A
type A/T MISSION (transmission model cord number: 90X5E) with A/T assembly (removed from the vehi-
cle).
● When removing, installing, disassembling, assembling, inspecting, etc. RE5R05A type A/T MISSION of
which model number is different, refer to the AT section of the applicable vehicle service manual.
● Do not judge commonality and compatibility of the part with this manual.
Components GCS00178

The symbols used in component figures are as shown below.

SAIA0749E

Precautions GCS0016B

● Always use the specified brand of ATF. Refer to the AT section of the applicable vehicle service manual.
● Use lint-free paper not cloth rags during work.
● Before proceeding with disassembly, thoroughly clean the outside of the A/T. It is important to prevent the
internal parts from becoming contaminated by dirt or other foreign matter.
● Disassembly should be done in a clean work area.
● Use lint-free paper for wiping parts clean. Common shop rags can leave fibers that could interfere with the
operation of the A/T.
● Place disassembled parts in order for easier and proper assembly.
● All parts should be carefully cleaned with a general purpose, non-flammable solvent before inspection or
reassembly.
● Gaskets, seals and O-rings should be replaced any time the A/T is disassembled.
● The valve body contains precision parts and requires extreme care when parts are removed and serviced.
Place disassembled valve body parts in order for easier and proper assembly. Care will also prevent
springs and small parts from becoming scattered or lost.
● Properly installed valves, sleeves, plugs, etc. will slide along bores in valve body under their own weight.
● Before assembly, apply a coat of recommended ATF to all parts. Apply petroleum jelly to protect O-rings
and seals, or hold bearings and washers in place during assembly. Do not use grease.
● Extreme care should be taken to avoid damage to O-rings, seals and gaskets when assembling.
● After overhaul, refill the transmission with new ATF.
● When the A/T drain plug is removed, only some of the fluid is drained. Old ATF will remain in torque con-
verter and ATF cooling system.

AT-2
 PREPARATION

PREPARATION PFP:00002
A
Special Service Tools GCS0016C

Tool number
Description
Tool name B
ST33400001 ● Installing rear oil seal
Drift ● Installing oil pump housing oil seal
a: 60 mm (2.36 in) dia. AT
b: 47 mm (1.85 in) dia.

D
NT086

KV31102400 Installing reverse brake return spring retainer

Clutch spring compressor E
a: 320 mm (12.60 in)
b: 174 mm (6.85 in)

NT423

ST25850000 Remove oil pump assembly G

Sliding hammer
a: 179 mm (7.05 in)
b: 70 mm (2.76 in)
c: 40 mm (1.57 in) H
d: M12X1.75P

NT422

I
Commercial Service Tools GCS00179

Tool name Description

J
Drift Installing manual shaft oil seal
a: 22 mm (0.87 in) dia.

NT083
L

AT-3
 A/T CONTROL SYSTEM

A/T CONTROL SYSTEM PFP:31036

Cross-Sectional View GCS0016D

SCIA5262E

1. Front planetary gear 2. Mid planetary gear 3. Rear planetary gear

4. Direct clutch 5. High and low reverse clutch 6. Reverse brake
7. Drum support 8. Forward brake 9. Low coast brake
10. Input shaft 11. Torque converter 12. Oil pump
13. Front brake 14. 3rd one-way clutch 15. Input clutch
16. 1st one-way clutch 17. Control valve with TCM 18. Forward one-way clutch
19. Rear extension 20. Output shaft

Function of Clutch and Brake GCS0016E

Name of the Part Abbreviation Function

Front brake FR/B Fastens the front sun gear.
Input clutch I/C Connects the input shaft, the front internal gear and the mid internal gear.
Direct clutch D/C Connects the rear carrier and the rear sun gear.
High and low reverse clutch HLR/C Connects the mid sun gear and the rear sun gear.
Reverse brake R/B Fastens the rear carrier.
Forward brake Fwd/B Fastens the mid sun gear.
Low coast brake LC/B Fastens the mid sun gear.
Allows the rear sun gear to turn freely forward relative to the mid sun gear but
1st one-way clutch 1st OWC
fastens it for reverse rotation.
Allows the mid sun gear to turn freely in the forward direction but fastens it for
Forward one-way clutch Fwd OWC
reverse rotation.
Allows the front sun gear to turn freely in the forward direction but fastens it for
3rd one-way clutch 3rd OWC
reverse rotation.

AT-4
 OVERHAUL

OVERHAUL PFP:00000
A
Components GCS0016K

AT

SCIA6697E

AT-5
 OVERHAUL

1. O-ring 2. Oil pump cover 3. O-ring

4. Oil pump housing 5. Self-sealing bolt 6. Torque converter
7. Converter housing 8. Oil pump housing oil seal 9. Bearing race
10. Needle bearing 11. O-ring 12. Front carrier assembly
13. Snap ring 14. Front sun gear 15. 3rd one-way clutch
16. Snap ring 17. Bearing race 18. Needle bearing
19. Seal ring 20. Input clutch assembly 21. Needle bearing
22. Rear internal gear assembly 23. Brake band 24. Mid carrier assembly
25. Needle bearing 26. Bearing race 27. Rear carrier assembly
28. Needle bearing 29. Mid sun gear 30. Seal ring
31. Rear sun gear 32. 1st one-way clutch 33. Snap ring
34. Needle bearing 35. High and low reverse clutch hub 36. Snap ring
37. Bearing race 38. Needle bearing

AT-6
 OVERHAUL

AT

SCIA7389E

1. Bearing race 2. High and low reverse clutch assem- 3. Needle bearing
bly
4. Direct clutch assembly 5. Needle bearing 6. Reverse brake dish plate

AT-7
 OVERHAUL

7. Reverse brake driven plate 8. N-spring 9. Snap ring

10. Reverse brake retaining plate 11. Reverse brake drive plate 12. Snap ring
13. Spring retainer 14. Return spring 15. Reverse brake piston
16. D-ring 17. D-ring

AT-8
 OVERHAUL

AT

SCIA7434E

1. Rear oil seal 2. Self-sealing bolt 3. Rear extension

4. Parking actuator support 5. Return spring 6. Parking pawl
7. Pawl shaft 8. Seal ring 9. Needle bearing

AT-9
 OVERHAUL

10. Revolution sensor 11. Parking gear 12. Output shaft

13. Bearing race 14. Needle bearing 15. Manual plate
16. Parking rod 17. Manual shaft oil seal 18. Manual shaft
19. O-ring 20. Band servo anchor end pin 21. Detent spring
22. Spacer 23. Seal ring 24. Snap ring
25. Return spring 26. O-ring 27. Servo assembly
28. Snap ring 29. Sub-harness 30. Control valve with TCM
31. Bracket 32. A/T fluid temperature sensor 2 33. Oil pan
34. Magnet 35. Drain plug 36. Drain plug gasket
37. Oil pan mounting bolt 38. Oil pan gasket 39. Terminal cord assembly
40. O-ring 41. Retaining pin 42. Transmission case
Refer to AT-2, "Components" for symbol mark in the figure.
However, refer to the following symbol for other.
*:
Apply Anaerobic Liquid Gasket (Loctite 518) or equivalent.

AT-10
 OVERHAUL

Oil Channel GCS0016L

AT

SCIA6387E

AT-11
 OVERHAUL

Locations of Adjusting Shims, Needle Bearings, Thrust Washers and Snap

Rings GCS0016M

SCIA7599E

AT-12
 DISASSEMBLY

DISASSEMBLY PFP:31020
A
Disassembly GCS0016N

CAUTION:
Do not disassemble parts behind Drum Support. Refer to AT-4, "Cross-Sectional View" . B
1. Drain ATF through drain plug.
2. Remove torque converter by holding it firmly and turing while
pulling straight out. AT

SCIA5010E

F
3. Check torque converter one-way clutch using a check tool as
shown in the figure.
a. Insert check tool into the groove of bearing support built into G
one-way clutch outer race.
b. When fixing bearing support with the check tool, rotate one- way
clutch spline using a screwdriver. H
c. Check that inner race rotates clockwise only. If not, replace
torque converter assembly.
I

SCIA3171E
M
4. Remove converter housing from transmission case.
CAUTION:
Be careful not to scratch converter housing.

SCIA3427E

AT-13
 DISASSEMBLY

5. Remove O-ring from input clutch assembly.

SCIA5011E

6. Remove tightening bolts for oil pump assembly and transmis-

sion case.

SCIA2300E

7. Attach the sliding hammers to oil pump assembly and extract it

evenly from transmission case.
CAUTION:
● Fully tighten the sliding hammer screws.

● Make sure that bearing race is installed to the oil pump

assembly edge surface.

SCIA4608E

8. Remove O-ring from oil pump assembly.

SCIA5172E

AT-14
 DISASSEMBLY

9. Remove bearing race from oil pump assembly.

A

AT

SCIA6529E

D
10. Remove needle bearing from front sun gear.

G
SCIA2808E

11. Remove front sun gear assembly from front carrier assembly. H
NOTE:
Remove front sun gear by rotating left/right.
I

SCIA5014E
K
12. Remove seal rings from input clutch assembly.

SCIA2470E

13. Remove front carrier assembly from rear carrier assembly. (With
input clutch assembly and rear internal gear assembly.)
CAUTION:
Be careful to remove it with needle bearing.

SCIA5015E

AT-15
 DISASSEMBLY

14. Loosen lock nut and remove band servo anchor end pin from
transmission case.

SCIA6512E

15. Remove brake band from transmission case.

SCIA2580E

● To prevent brake linings from cracking or peeling, do not

stretch the flexible band unnecessarily. When removing
the brake band, always secure it with a clip as shown in
the figure at right.
Leave the clip in position after removing the brake band.
● Check brake band facing for damage, cracks, wear or
burns.

SAT655

16. Remove mid carrier assembly and rear carrier assembly as a

unit.

SCIA5017E

17. Remove mid carrier assembly from rear carrier assembly.

SCIA5697E

AT-16
 DISASSEMBLY

18. Remove needle bearing (front side) from mid carrier assembly.
A

AT

SCIA2805E
D
19. Remove needle bearing (rear side) from mid carrier assembly.

G
SCIA2804E

20. Remove bearing race from rear carrier assembly. H

SCIA5175E K

21. Remove needle bearing from rear carrier assembly.

L

SCIA2803E

22. Remove mid sun gear assembly, rear sun gear assembly and
high and low reverse clutch hub as a unit.
CAUTION:
Be careful to remove then with bearing race and needle
bearing.

SCIA5018E

AT-17
 DISASSEMBLY

23. Remove high and low reverse clutch assembly from direct clutch
assembly.
CAUTION:
Make sure that needle bearing is installed to the high and
low reverse clutch assembly edge surface.

SCIA2306E

24. Remove direct clutch assembly from transmission case.

SCIA5019E

25. Remove needle bearing from drum support edge surface.

SCIA5198E

26. Remove snap ring from A/T assembly harness connector.

SCIA5021E

27. Push A/T assembly harness connector.

CAUTION:
Be careful not to damage connector.

SCIA5022E

AT-18
 DISASSEMBLY

28. Remove oil pan and oil pan gasket.

A

AT

SCIA2308E
D
29. Check foreign materials in oil pan to help determine causes of
malfunction. If the ATF is very dark, smells burned, or contains
foreign particles, the frictional material (clutches, band) may E
need replacement. A tacky film that will not wipe clean indicates
varnish build up. Varnish can cause valves, servo, and clutches
to stick and can inhibit pump pressure.
F

G
SCIA5199E

30. Remove magnets from oil pan. H

SCIA5200E K

31. Disconnect A/T fluid temperature sensor 2 connector.

CAUTION: L
Be careful not to damage connector.

SCIA5023E

32. Straighten terminal clips to free terminal cord assembly and A/T
fluid temperature sensor 2 harness.

SCIA5446E

AT-19
 DISASSEMBLY

33. Disconnect revolution sensor connector.

CAUTION:
Be careful not to damage connector.

SCIA7524E

34. Straighten terminal clip to free revolution sensor harness.

SCIA7526E

35. Remove bolts A, B and C from control valve with TCM.

Bolt symbol Length mm (in) Number of bolts
A 42 (1.65) 5
B 55 (2.17) 6
C 40 (1.57) 1

SCIA5025E

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.

SCIA5260E

37. Remove A/T fluid temperature sensor 2 with bracket from con-
trol valve with TCM.

SCIA5301E

AT-20
 DISASSEMBLY

38. Remove bracket from A/T fluid temperature sensor 2.

A

AT

SCIA5264E
D
39. Remove O-ring from A/T assembly harness connector.

G
SCIA5155E

40. Disconnect TCM connectors. H

CAUTION:
Be careful not to damage connectors.
I

SCIA5447E K

41. Remove A/T assembly harness connector from control valve

with TCM using a flat-bladed screwdriver.
L

SCIA5448E

42. Disconnect TCM connector and park/neutral position switch

connector.
CAUTION:
Be careful not to damage connectors.

SCIA5449E

AT-21
 DISASSEMBLY

43. Remove tightening bolts for rear extension assembly and trans-
mission case.

SCIA6941E

44. Tap rear extension assembly with a soft hammer.

SCIA5028E

45. Remove rear extension assembly from transmission case.

SCIA5029E

46. Remove bearing race from output shaft.

SCIA5245E

47. Remove output shaft from transmission case by rotating left/

right.

SCIA5030E

AT-22
 DISASSEMBLY

48. Remove parking gear from output shaft.

A

AT

SCIA5247E
D
49. Remove seal rings from output shaft.

G
SCIA5209E

50. Remove needle bearing from transmission case. H

SCIA5031E K

51. Remove revolution sensor from transmission case.

CAUTION: L
● 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

M
edge magnetic area.
● Do not place in an area affected by magnetism.

SCIA2320E

52. 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.
53. Remove reverse brake retaining plate from transmission case.
● Check facing for burns, cracks or damage. If necessary,
replace the plate.
SCIA5032E

AT-23
 DISASSEMBLY

54. Remove N-spring from transmission case.

SCIA5214E

55. 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.

SCIA2322E

56. Remove snap ring (fixing spring retainer) using a flat-bladed

screwdriver.

SCIA2323E

57. Remove spring retainer and return spring from transmission

case.

SCIA2324E

58. Remove seal rings from drum support.

SCIA3333E

AT-24
 DISASSEMBLY

59. Remove needle bearing from drum support edge surface.

A

AT

SCIA2796E
D
60. Remove reverse brake piston from transmission case with com-
pressed air. Refer to AT-11, "Oil Channel" .
CAUTION: E
Care should be taken not to abruptly blow air. It makes pis-
tons incline, as the result, it becomes hard to disassemble
the pistons.
F

SCIA5047E
K
61. Remove D-rings from reverse brake piston.

SCIA5340E

62. Use a pin punch (4 mm dia. commercial service tool) to knock

out retaining pin.

SCIA2328E

AT-25
 DISASSEMBLY

63. Remove manual shaft retaining pin with a pair of nippers.

SCIA2329E

64. Remove manual plate (with parking rod) from manual shaft.

SCIA5715E

65. Remove parking rod from manual plate.

SCIA5220E

66. Remove manual shaft from transmission case.

SCIA5716E

67. Remove manual shaft oil seals using a flat-bladed screwdriver.

CAUTION:
Be careful not to scratch transmission case.

SCIA2331E

AT-26
 DISASSEMBLY

68. Remove detent spring and spacer from transmission case.

A

AT

SCIA5248E
D
69. Using a pair of snap ring pliers, remove snap ring from transmis-
sion case.
E

G
SCIA2333E

70. Remove servo assembly (with return spring) from transmission H

case.

SCIA5679E K

71. Remove return spring from servo assembly.

L

SCIA5717E

72. Remove O-rings from servo assembly.

SCIA5719E

AT-27
 DISASSEMBLY

73. Remove needle bearing from rear extension.

SCIA6021E

74. Remove parking actuator support from rear extension.

SCIA3423E

75. Remove parking pawl (with return spring) and pawl shaft from
rear extension.

SCIA3424E

76. Remove return spring from parking pawl.

SCIA2445E

77. Remove rear oil seal from rear extension using a flat-bladed
screwdriver.
CAUTION:
Be careful not to scratch rear extension.

SCIA3524E

AT-28
 REPAIR FOR COMPONENT PARTS

REPAIR FOR COMPONENT PARTS PFP:00000

A
Oil Pump GCS0016O

COMPONENTS
B

AT

G
SCIA6699E

1. O-ring 2. Oil pump cover 3. O-ring

H
4. Oil pump housing 5. Oil pump housing oil seal

DISASSEMBLY
1. Remove oil pump housing from oil pump cover. I

SCIA6388E L

2. Remove oil pump housing oil seal using a flat-bladed screw-

driver.
M
CAUTION:
Be careful not to scratch oil pump housing.

SCIA2840E

AT-29
 REPAIR FOR COMPONENT PARTS

3. Remove O-ring from oil pump housing.

SCIA2841E

4. Remove O-ring from oil pump cover.

SCIA5230E

ASSEMBLY
1. Install O-ring to oil pump cover.
CAUTION:
● Do not reuse O-ring.

● Apply ATF to O-ring.

SCIA5230E

2. Install O-ring to oil pump housing.

CAUTION:
● Do not reuse O-ring.

● Apply ATF to O-ring.

SCIA2841E

AT-30
 REPAIR FOR COMPONENT PARTS

3. Using the drift, install oil pump housing oil seal to the oil pump
housing until it is flush. A
CAUTION:
● Do not reuse oil seal.

● Apply ATF to oil seal. B

AT

SCIA4609E

D
4. Install oil pump housing to oil pump cover.
5. Tighten bolts to the specified torque in numerical order shown in
E
the figure after temporarily tightening them.
: 9.0 N·m (0.92 kg-m, 80 in-lb.)
F

SCIA6388E
H

AT-31
 REPAIR FOR COMPONENT PARTS

Front Sun Gear, 3rd One-way Clutch GCS0016P

COMPONENTS

SCIA3114E

1. Front sun gear 2. 3rd one-way clutch 3. Snap ring

DISASSEMBLY
1. Using a flat-bladed screwdriver, remove snap ring from front sun
gear.

SCIA3110E

2. Remove 3rd one-way clutch from front sun gear.

SCIA3111E

INSPECTION
3rd One-way Clutch
● Check frictional surface for wear or damage.
CAUTION:
If necessary, replace the 3rd one-way clutch.
Front Sun Gear Snap Ring
● Check for deformation, fatigue or damage.

AT-32
 REPAIR FOR COMPONENT PARTS

CAUTION:
If necessary, replace the snap ring. A
Front Sun Gear
● Check for deformation, fatigue or damage.
B
CAUTION:
If necessary, replace the front sun gear.
ASSEMBLY AT
1. Install 3rd one-way clutch in front sun gear.
CAUTION:
Apply ATF to 3rd one-way clutch. D

F
SCIA3111E

2. Using a flat-bladed screwdriver, install snap ring in front sun

gear. G

SCIA3110E
J
3. Check operation of 3rd one-way clutch.
a. Hold oil pump assembly and turn front sun gear.
K
b. Check 3rd one-way clutch for correct locking and unlocking
directions.
CAUTION:
If not as shown in the figure, check installation direction of L
3rd one-way clutch.

SCIA3131E

AT-33
 REPAIR FOR COMPONENT PARTS

Front Carrier, Input Clutch, Rear Internal Gear GCS0016Q

COMPONENTS

SCIA5426E

1. Seal ring 2. O-ring 3. Needle bearing

4. Bearing race 5. Front carrier assembly 6. Snap ring
7. Snap ring 8. Retaining plate 9. Driven plate
10. Input clutch drum 11. Drive plate 12. Rear internal gear assembly

AT-34
 REPAIR FOR COMPONENT PARTS

DISASSEMBLY
1. Compress snap ring using 2 flat-bladed screwdrivers. A
2. Remove front carrier assembly and input clutch assembly from
rear internal gear assembly.
3. Remove front carrier assembly from input clutch assembly. B

AT

SCIA7475E
D

a. Remove bearing race from front carrier assembly.

E

SCIA2847E
H
b. Remove snap ring from front carrier assembly.
CAUTION:
Do not expand snap ring excessively. I

K
SCIA5476E

4. Disassemble input clutch assembly. L

a. Remove O-ring and seal rings from input clutch assembly.

SCIA5235E

AT-35
 REPAIR FOR COMPONENT PARTS

b. Remove needle bearing from input clutch assembly.

SCIA2853E

c. Using a flat-bladed screwdriver, remove snap ring from input

clutch drum.
d. Remove drive plates, driven plates and retaining plate from input
clutch drum.

SCIA2864E

INSPECTION
Front Carrier Snap Ring
● Check for deformation, fatigue or damage.
CAUTION:
If necessary, replace the snap ring.
Input Clutch Snap Ring
● Check for deformation, fatigue or damage.
CAUTION:
If necessary, replace the input clutch assembly.
Input Clutch Drum
● Check for deformation, fatigue or damage or burns.
CAUTION:
If necessary, replace the input clutch assembly.
Input Clutch Drive Plates
● Check facing for burns, cracks or damage.
CAUTION:
If necessary, replace the input clutch assembly.
Input Clutch Retaining Plate and Driven Plates
● Check facing for burns, cracks or damage.
CAUTION:
If necessary, replace the input clutch assembly.
Front Carrier
● Check for deformation, fatigue or damage.
CAUTION:
If necessary, replace the front carrier assembly.
Rear Internal Gear
● Check for deformation, fatigue or damage.
CAUTION:
If necessary, replace the rear internal gear assembly.
AT-36
 REPAIR FOR COMPONENT PARTS

ASSEMBLY
1. Install input clutch. A
a. Install drive plates, driven plates and retaining plate in input clutch drum.
CAUTION:
Take care with order of plates. B
b. Using a flat-bladed screwdriver, install snap ring in input clutch
drum.
AT

E
SCIA2864E

c. Install needle bearing in input clutch assembly. F

CAUTION:
● Take care with the direction of needle bearing. Refer to
AT-12, "Locations of Adjusting Shims, Needle Bearings, G
Thrust Washers and Snap Rings" .
● Apply petroleum jelly to needle bearing.

SCIA2853E I

d. Install O-ring and seal rings in input clutch assembly.

CAUTION: J
● Do not reuse O-ring and seal rings.

● Apply ATF to O-ring.

● Apply petroleum jelly to seal rings. K

SCIA5235E

M
2. Install front carrier assembly.
a. Install snap ring to front carrier assembly.
CAUTION:
Do not expand snap ring excessively.

SCIA5476E

AT-37
 REPAIR FOR COMPONENT PARTS

b. Install bearing race in front carrier assembly.

CAUTION:
Apply petroleum jelly to bearing race.
c. Install front carrier assembly to input clutch assembly.

SCIA2847E

3. Compress snap ring using 2 flat-bladed screwdrivers.

4. Install front carrier assembly and input clutch assembly to rear
internal gear assembly.

SCIA7475E

AT-38
 REPAIR FOR COMPONENT PARTS

Mid Sun Gear, Rear Sun Gear, High and Low Reverse Clutch Hub GCS0016R

COMPONENTS A

AT

SCIA2851E G
1. Needle bearing 2. Bearing race 3. Snap ring
4. High and low reverse clutch hub 5. Needle bearing 6. Snap ring
7. 1st one-way clutch 8. Rear sun gear 9. Seal ring H
10. Mid sun gear

DISASSEMBLY
I
1. Remove needle bearing and bearing race from high and low
reverse clutch hub.

L
SCIA2854E

2. Using a pair of snap ring pliers, remove snap ring from mid sun
gear assembly. M
CAUTION:
Do not expand snap ring excessively.

SCIA2855E

AT-39
 REPAIR FOR COMPONENT PARTS

3. Remove high and low reverse clutch hub from mid sun gear
assembly.

SCIA2856E

a. Remove needle bearing from high and low reverse clutch hub.

SCIA2857E

4. Remove rear sun gear assembly from mid sun gear assembly.

SCIA2858E

a. Using a flat-bladed screwdriver, remove snap ring from rear sun

gear.

SCIA2859E

AT-40
 REPAIR FOR COMPONENT PARTS

b. Remove 1st one-way clutch from rear sun gear.

A

AT

SCIA4633E

D
5. Remove seal rings from mid sun gear.

G
SCIA2861E

INSPECTION H
High and Low Reverse Clutch Hub Snap Ring, Rear Sun Gear Snap Ring
● Check for deformation, fatigue or damage.
CAUTION: I
If necessary, replace the snap ring.
1st One-way Clutch
J
● Check frictional surface for wear or damage.
CAUTION:
If necessary, replace the 1st one-way clutch.
K
Mid Sun Gear
● Check for deformation, fatigue or damage.
CAUTION: L
If necessary, replace the mid sun gear.
Rear Sun Gear
● Check for deformation, fatigue or damage. M
CAUTION:
If necessary, replace the rear sun gear.
High and Low Reverse Clutch Hub
● Check for deformation, fatigue or damage.
CAUTION:
If necessary, replace the high and low reverse clutch hub.

AT-41
 REPAIR FOR COMPONENT PARTS

ASSEMBLY
1. Install seal rings to mid sun gear.
CAUTION:
● Do not reuse seal rings.

● Apply petroleum jelly to seal rings.

SCIA2861E

2. Install 1st one-way clutch to rear sun gear.

CAUTION:
Apply petroleum jelly to 1st one-way clutch.

SCIA4633E

3. Using a flat-bladed screwdriver, install snap ring to rear sun

gear.

SCIA2859E

4. Install rear sun gear assembly to mid sun gear assembly.

SCIA2858E

AT-42
 REPAIR FOR COMPONENT PARTS

5. Install needle bearing to high and low reverse clutch hub.

CAUTION: A
● Take care with the direction of needle bearing. Refer to
AT-12, "Locations of Adjusting Shims, Needle Bearings,
Thrust Washers and Snap Rings" . B
● Apply petroleum jelly to needle bearing.

AT

SCIA2857E

D
6. Install high and low reverse clutch hub to mid sun gear assem-
bly.
E

G
SCIA2856E

7. Using a pair of snap ring pliers, install snap ring to mid sun gear H
assembly.
CAUTION:
Do not expand snap ring excessively.
I

SCIA2855E
K
8. Check operation of 1st one-way clutch.
a. Hold mid sun gear and turn rear sun gear.
L
b. Check 1st one-way clutch for correct locking and unlocking
directions.
CAUTION:
If not as shown in the figure, check installation direction of M
1st one-way clutch.

SCIA3132E

9. Install needle bearing and bearing race to high and low reverse
clutch hub.
CAUTION:
● Take care with the direction of needle bearing. Refer to
AT-12, "Locations of Adjusting Shims, Needle Bearings,
Thrust Washers and Snap Rings" .
● Apply petroleum jelly to needle bearing.

SCIA2854E

AT-43
 REPAIR FOR COMPONENT PARTS

High and Low Reverse Clutch GCS0016S

COMPONENTS

SCIA5045E

1. High and low reverse clutch drum 2. Driven plate 3. Retaining plate
4. Snap ring 5. Drive plate 6. Bearing race

DISASSEMBLY
1. Remove bearing race from high and low reverse clutch drum.

SCIA5215E

2. Using a flat-bladed screwdriver, remove snap ring from high and

low reverse clutch drum.
3. Remove drive plates, driven plates and retaining plate from high
and low reverse clutch drum.

SCIA2868E

AT-44
 REPAIR FOR COMPONENT PARTS

INSPECTION
● Check the following, and replace high and low reverse clutch assembly if necessary. A

High and Low Reverse Clutch Snap Ring

● Check for deformation, fatigue or damage. B
High and Low Reverse Clutch Drive Plates
● Check facing for burns, cracks or damage.
AT
High and Low Reverse Clutch Retaining Plate and Driven Plates
● Check facing for burns, cracks or damage.
D
ASSEMBLY
1. Install drive plates, driven plates and retaining plate in high and low reverse clutch drum.
CAUTION: E
Take care with order of plates.
2. Using a flat-bladed screwdriver, install snap ring in high and low
reverse clutch drum.
F

SCIA2868E

I
3. Install bearing race to high and low reverse clutch drum.
CAUTION:
Apply petroleum jelly to bearing race.
J

L
SCIA5215E

AT-45
 REPAIR FOR COMPONENT PARTS

Direct Clutch GCS0016T

COMPONENTS

SCIA5046E

1. Direct clutch drum 2. Driven plate 3. Retaining plate

4. Snap ring 5. Drive plate

DISASSEMBLY
1. Using a flat-bladed screwdriver, remove snap ring from direct
clutch drum.
2. Remove drive plates, driven plates and retaining plate from
direct clutch drum.

SCIA2868E

INSPECTION
● Check the following, and replace direct clutch assembly if necessary.
Direct Clutch Snap Ring
● Check for deformation, fatigue or damage.
Direct Clutch Drive Plates
● Check facing for burns, cracks or damage.
Direct Clutch Retaining Plate and Driven Plates
● Check facing for burns, cracks or damage.

AT-46
 REPAIR FOR COMPONENT PARTS

ASSEMBLY
1. Install drive plates, driven plates and retaining plate in direct clutch drum. A
CAUTION:
Take care with order of plates.
2. Using a flat-bladed screwdriver, install snap ring in direct clutch B
drum.

AT

SCIA2868E
E

AT-47
 ASSEMBLY

ASSEMBLY PFP:00000

Assembly (1) GCS0016U

1. As shown in the figure, use a drift [commercial service tool φ22

mm (0.87 in)] to drive manual shaft oil seals into the transmis-
sion case until it is flush.
CAUTION:
● Do not reuse manual shaft oil seals.

● Apply ATF to manual shaft oil seals.

SCIA5259E

2. Install detent spring and spacer in transmission case.

: 7.9 N·m (0.81 kg-m, 70 in-lb)

SCIA5248E

3. Install manual shaft to transmission case.

SCIA5716E

4. Install parking rod to manual plate.

SCIA5220E

AT-48
 ASSEMBLY

5. Install manual plate (with parking rod) to manual shaft.

A

AT

SCIA5715E

D
6. Install retaining pin into the manual plate and manual shaft.
a. Fit pinhole of the manual plate to pinhole of the manual shaft with a pin punch.
b. Use a hammer to tap the retaining pin into the manual plate. E
CAUTION:
● Drive retaining pin to 2±0.5 mm (0.08±0.020 in) over the
manual plate. F
● Do not reuse retaining pin.

SCIA5297E H

7. Install retaining pin into the transmission case and manual shaft.
a. Fit pinhole of the transmission case to pinhole of the manual shaft with a pin punch. I
b. Use a hammer to tap the retaining pin into the transmission
case.
CAUTION: J
● Drive retaining pin to 5±1 mm (0.20±0.04 in) over the
transmission case.
● Do not reuse retaining pin. K

L
SCIA2427E

8. Install O-rings to servo assembly. M

CAUTION:
Do not reuse O-rings.
Apply petroleum jelly to O-rings.

SCIA5719E

AT-49
 ASSEMBLY

9. Install return spring to servo assembly.

SCIA5717E

10. Install servo assembly in transmission case.

SCIA5679E

11. Using a pair of snap ring pliers, install snap ring to transmission
case.

SCIA2333E

12. Install D-rings in reverse brake piston.

CAUTION:
● Do not reuse D-rings.

● Apply ATF to D-rings.

SCIA5340E

13. Install reverse brake piston in transmission case.

SCIA2325E

AT-50
 ASSEMBLY

14. Install needle bearing to drum support edge surface.

A
CAUTION:
● Take care with the direciton of needle bearing. Refer to
AT-12, "Locations of Adjusting Shims, Needle Bearings,
Thrust Washers and Snap Rings" . B
● Apply petroleum jelly to needle bearing.

AT

SCIA2796E
D
15. Install seal rings to drum support.
CAUTION:
● Do not reuse seal rings. E
● Apply petroleum jelly to seal rings.

G
SCIA3333E

16. Install spring retainer and return spring in transmission case. H

SCIA2324E K

17. Set the SST on spring retainer and install snap ring (fixing spring
retainer) in transmission case while compressing return spring.
L
CAUTION:
Securely assemble them using a flat-bladed screwdriver so
that snap ring tension is slightly weak.
M

SCIA6700E

AT-51
 ASSEMBLY

18. Install reverse brake drive plates, driven plates and dish plate in
transmission case.
CAUTION:
Take care with order of plates.

SCIA5250E

19. Assemble N-spring.

20. Install reverse brake retaining plate in transmission case.

SCIA5249E

21. Install snap ring in transmission case.

SCIA2439E

AT-52
 ASSEMBLY

22. Measure clearance between retaining plate and snap ring. If not
within specified clearance, select proper retaining plate. Refer to A
“Parts Information” for retaining plate selection.
Specified clearance “A”:
Standard: Refer to AT-70, "Reverse Brake" . B

AT

SCIA3129E

D
23. Install needle bearing to transmission case.
CAUTION:
● Take care with the direciton of needle bearing. Refer to
E
AT-12, "Locations of Adjusting Shims, Needle Bearings,
Thrust Washers and Snap Rings" .
● Apply petroleum jelly to needle bearing.
F

G
SCIA5031E

24. Install revolution sensor to transmission case.

H
CAUTION:
● Do not subject it to impact by dropping or hitting it.

● Do not disassemble.
I
● 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.
J
: 5.8 N·m (0.59 kg-m, 51 in-lb)
SCIA2320E
K
25. As shown in the figure, use the drift to drive rear oil seal into the
rear extension until it is flush.
CAUTION: L
● Do not reuse rear oil seal.

● Apply ATF to rear oil seal.

SCIA6694E

26. Install return spring to parking pawl.

SCIA2445E

AT-53
 ASSEMBLY

27. Install parking pawl (with return spring) and pawl shaft to rear
extension.

SCIA3424E

28. Install parking actuator support to rear extension.

SCIA3423E

29. Install needle bearing to rear extension.

CAUTION:
● Take care with the direciton of needle bearing. Refer to
AT-12, "Locations of Adjusting Shims, Needle Bearings,
Thrust Washers and Snap Rings" .
● Apply petroleum jelly to needle bearing.

SCIA6021E

30. Install seal rings to output shaft.

CAUTION:
● Do not reuse seal rings.

● Apply petroleum jelly to seal rings.

SCIA5209E

31. Install parking gear to output shaft.

SCIA5247E

AT-54
 ASSEMBLY

32. Install output shaft in transmission case.

A
CAUTION:
Be careful not to mistake front for rear because both sides
looks similar. (Thinner end is front side.)
B

AT

SCIA5030E
D
33. Install bearing race to output shaft.

G
SCIA5245E

34. Apply Anaerobic Liquid Gasket (Loctite 518) or equivalent to H

rear extension assembly as shown in the figure.
CAUTION:
Completely remove all moisture, oil and old sealant, etc. I
from the transmission case and rear extension assembly
mounting surfaces.

SCIA4635E K

35. Install rear extension assembly to transmission case.

CAUTION: L
Insert the tip of parking rod between the parking pawl and
the parking actuator support when assembling the rear
extension assembly.
M

SCIA5029E

36. Tighten rear extension assembly mounting bolts to specified

torque.
CAUTION:
Do not reuse self-sealing bolts.
Rear extension assembly mounting bolt:
: 52 N·m (5.3 kg-m, 38 ft-lb)
Self-sealing bolt:
: 61 N·m (6.2 kg-m, 45 ft-lb)
SCIA6941E

AT-55
 ASSEMBLY

37. Install needle bearing in drum support edge surface.

CAUTION:
● Take care with the direciton of needle bearing. Refer to
AT-12, "Locations of Adjusting Shims, Needle Bearings,
Thrust Washers and Snap Rings" .
● Apply petroleum jelly to needle bearing.

SCIA5198E

38. Install direct clutch assembly in reverse brake.

CAUTION:
Make sure that drum support edge surface and direct clutch
inner boss edge surface come to almost same place.

SCIA5019E

39. Install high and low reverse clutch assembly in direct clutch
assembly.

SCIA2306E

40. Using a flat-bladed screwdriver, align the drive plate.

SCIA3169E

41. Install high and low reverse clutch hub, mid sun gear assembly
and rear sun gear assembly as a unit.

SCIA5018E

AT-56
 ASSEMBLY

CAUTION: A
Check that portion “A” of high and low reverse clutch drum
protrudes approximately 2 mm (0.08 in) beyond portion “B”
of rear sun gear.
B

AT

D
SCIA3130E

42. Install needle bearing in rear carrier assembly.

E
CAUTION:
● Take care with the direciton of needle bearing. Refer to
AT-12, "Locations of Adjusting Shims, Needle Bearings,
Thrust Washers and Snap Rings" . F
● Apply petroleum jelly to needle bearing.

SCIA2803E
H
43. Install bearing race in rear carrier assembly.
CAUTION:
Apply petroleum jelly to bearing race. I

K
SCIA5175E

44. Install rear carrier assembly in direct clutch drum. L

SCIA2462E

AT-57
 ASSEMBLY

45. Install needle bearing (rear side) to mid carrier assembly.

CAUTION:
● Take care with the direciton of needle bearing. Refer to
AT-12, "Locations of Adjusting Shims, Needle Bearings,
Thrust Washers and Snap Rings" .
● Apply petroleum jelly to needle bearing.

SCIA2804E

46. Install needle bearing (front side) to mid carrier assembly.

CAUTION:
● Take care with the direciton of needle bearing. Refer to
AT-12, "Locations of Adjusting Shims, Needle Bearings,
Thrust Washers and Snap Rings" .
● Apply petroleum jelly to needle bearing.

SCIA2805E

47. Install mid carrier assembly in rear carrier assembly.

SCIA5017E

48. Install front carrier assembly, input clutch assembly and rear
internal gear as a unit.

SCIA5015E

49. Install seal rings in input clutch assembly.

CAUTION:
● Do not reuse seal rings.

● Apply petroleum jelly to seal rings.

SCIA2470E

AT-58
 ASSEMBLY

50. Install band servo anchor end pin and lock nut in transmission
case. A
CAUTION:
Do not reuse band servo anchor end pin.
B

AT

SCIA6512E
D
51. Install brake band in transmission case.
CAUTION:
Assemble it so that identification to avoid incorrect installa- E
tion faces servo side.

G
SCIA5498E

52. Install front sun gear to front carrier assembly. H

CAUTION:
Apply ATF to front sun gear bearing and 3rd one-way clutch
end bearing. I

SCIA5014E K

53. Install needle bearing to front sun gear.

CAUTION: L
Apply petroleum jelly to needle bearing.

SCIA2808E

54. Adjust brake band tilting using clips so that brake band contacts
front sun gear drum evenly.

SCIA5033E

AT-59
 ASSEMBLY

55. Adjust brake band.

a. Loosen lock nut.
b. Tighten band servo anchor end pin to specified torque.

: 5.0 N·m (0.51 kg-m, 44 in-lb)

c. Back of band servo anchor end pin three turns.
d. Holding band servo anchor end pin, tighten lock nut to specified
torque.

: 46 N·m (4.7 kg-m, 34 ft-lb) SCIA5498E

Adjustment GCS0016V

TOTAL END PLAY

● Measure clearance between front sun gear and bearing race for
oil pump cover.
● Select proper thickness of bearing race so that end play is within
specifications.

SCIA2810E

1. Measure dimensions “K” and “L” and then calculate dimension

“J”.

SCIA7073E

a. Measure dimension “K”.

SCIA7074E

AT-60
 ASSEMBLY

b. Measure dimension “L”.

c. Calculate dimension “J”. A
“J”: Distance between oil pump fitting surface of
transmission case and needle bearing mating surface
of front sun gear. B
J=K–L
AT

SCIA5352E

D
2. Measure dimensions “M1 ” and “M2 ” and then calculate dimen-
sion “M”.
E

G
SCIA3125E

a. Place bearing race and needle bearing on oil pump assembly. H

SCIA3124E K
b. Measure dimension “M1 ”.
L

SCIA3126E

c. Measure dimension “M2 ”.

SCIA3127E

AT-61
 ASSEMBLY

d. Calculate dimension “M”.

“M”: Distance between transmission case fitting sur-
face of oil pump and needle bearing on oil pump.
M = M1 – M2

SCIA3125E

3. Adjust total end play “T1 ”.

T1 = J – M
Total end play “T1 ”: Refer to AT-70, "Total End Play" .
● Select proper thickness of bearing race so that total end play
is within specifications. Refer to “Parts Information” for bear-
ing race selection.

SCIA2810E

Assembly (2) GCS0016W

1. Install O-ring to oil pump assembly.

CAUTION:
● Do not reuse O-ring.

● Apply ATF to O-ring.

SCIA5172E

2. Install bearing race to oil pump assembly.

CAUTION:
Apply petroleum jelly to bearing race.

SCIA6529E

AT-62
 ASSEMBLY

3. Install oil pump assembly in transmission case.

CAUTION: A
Apply ATF to oil pump bearing.

AT

SCIA2811E

D
4. Apply Liquid Gasket (Three Bond 1215) or equivalent to oil
pump assembly as shown in the figure.
CAUTION: E
Completely remove all moisture, oil and old sealant, etc.
from the oil pump mounting bolts and oil pump mounting
bolt mounting surfaces.
F

G
SCIA4636E

5. Tighten oil pump mounting bolts to specified torque. H

CAUTION:
Apply ATF to oil pump bushing.
: 48 N·m (4.9 kg-m, 35 ft-lb) I

SCIA2300E
K
6. Install O-ring to input clutch assembly.
CAUTION:
● Do not reuse O-ring. L
● Apply ATF to O-ring.

SCIA5011E

7. Install converter housing to transmission case.

CAUTION:
Do not reuse self-sealing bolt.
Converter housing mounting bolt:
: 52 N·m (5.3 kg-m, 38 ft-lb)
Self-sealing bolt:
: 61 N·m (6.2 kg-m, 45 ft-lb)

SCIA3427E

AT-63
 ASSEMBLY

8. Make sure that brake band does not close turbine revolution
sensor hole.

SCIA5034E

9. Install control valve with TCM.

a. Connect TCM connector and park/neutral position switch con-
nector.

SCIA5449E

b. Install A/T assembly harness connector from control valve with

TCM.

SCIA5450E

c. Connect TCM connectors.

SCIA5447E

AT-64
 ASSEMBLY

d. Install O-ring to A/T assembly harness connector.

CAUTION: A
● Do not reuse O-ring.

● Apply ATF to O-ring.

B

AT

SCIA5155E

D
e. Install A/T fluid temperature sensor 2 to bracket.

G
SCIA5264E

f. Install A/T fluid temperature sensor 2 (with bracket) in control H

valve with TCM.
CAUTION:
Adjust bolt hole of bracket to bolt hole of control valve.
I
: 7.9 N·m (0.81 kg-m, 70 in-lb)

SCIA5301E
K
g. Install control valve with TCM in transmission case.
CAUTION:
● Make sure that turbine revolution sensor securely installs L
turbine revolution sensor hole.
● Hang down revolution sensor harness toward outside so
as not to disturb installation of control valve with TCM. M
● Adjust A/T assembly harness connector of control valve
with TCM to terminal hole of transmission case.

SCIA5034E

AT-65
 ASSEMBLY

● Assemble it so that manual valve cutout is engaged with

manual plate projection.

SCIA5035E

h. Install bolts A, B and C to control valve with TCM.

Bolt symbol Length mm (in) Number of bolts
A 42 (1.65) 5
B 55 (2.17) 6
C 40 (1.57) 1

SCIA5025E

i. Tighten bolt 1, 2 and 3 temporarily to prevent dislocation. After

that tighten them in order (1 → 2 → 3), and then tighten other
bolts.

: 7.9 N·m (0.81 kg-m, 70 in-lb)

SCIA5037E

10. Connect A/T fluid temperature sensor 2 connector.

SCIA5023E

AT-66
 ASSEMBLY

11. Securely fasten terminal cord assembly and A/T fluid tempera-
ture sensor 2 harness with terminal clips. A

AT

SCIA5446E

D
12. Connect revolution sensor connector.

G
SCIA7524E

13. Securely fasten revolution sensor harness with terminal clip. H

SCIA7526E
K
14. Pull down A/T assembly harness connector.
CAUTION:
Be careful not to damage connector. L

SCIA5299E

15. Install snap ring to A/T assembly harness connector.

SCIA5300E

AT-67
 ASSEMBLY

16. Install magnets in oil pan.

SCIA5200E

17. Install oil pan to transmission case.

a. Install oil pan gasket to transmission case.
CAUTION:
● Do not reuse oil pan gasket.

● Install it in the direction to align hole positions.

● Completely remove all moisture, oil and old gasket, etc. from oil pan gasket mounting surface.

b. Install oil pan to transmission case.

CAUTION:
● Install it so that drain plug comes to the position as
shown in the figure.
● Be careful not to pinch harnesses.

● Completely remove all moisture, oil and old gasket, etc.

from oil pan mounting surface.

SCIA2308E

c. Tighten oil pan mounting bolts to the specified torque in numeri-

cal order shown in the figure after temporarily tightening them.
CAUTION:
Do not reuse oil pan mounting bolts.

: 7.9 N·m (0.81 kg-m, 70 in-lb)

18. Install drain plug to oil pan.
CAUTION:
Do not reuse drain plug gasket.
: 34 N·m (3.5 kg-m, 25 ft-lb) SCIA4113E

19. Install torque converter.

a. Pour ATF into torque converter.
● Approximately 2 liter (1-3/4 Imp qt) of fluid is required for
a new torque converter.
● When reusing old torque converter, add the same amount
of fluid as was drained.

SAT428DA

AT-68
 ASSEMBLY

b. Install torque converter while aligning notches of torque con-

verter with notches of oil pump. A
CAUTION:
Install torque converter while rotating it.
B

AT

SCIA5010E

D
c. Measure distance “A” to check that torque converter is in proper
position.
Distance “A”: 25.0 mm (0.98 in) or more E

G
SCIA5694E

AT-69
 SERVICE DATA AND SPECIFICATIONS (SDS)

SERVICE DATA AND SPECIFICATIONS (SDS) PFP:00030

Reverse Brake GCS00175

Model code number 90X5E

Number of drive plates 6
Number of driven plates 6
Clearance mm (in) Standard 0.7 - 1.1 (0.028 - 0.043)

Total End Play GCS00176

Total end play mm (in) 0.25 - 0.55 (0.0098 - 0.0217)

AT-70