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Home >> Toyota >> 1993 >> Paseo Automatic >> Repair and Diagnosis >> External Pages >> Different car >> Section 61 (Overhaul - A-241E/H/L & A-243E) >> Transaxle Disassembly

Transaxle Disassembly

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  1. On A-241H, remove bolts and nuts on transfer case assembly. Remove transfer case assembly from transaxle. Remove apply gasket. Using Remover/Installer (09520-32012), remove differential side gear intermediate shaft. See Fig 7.
  2. On all models, remove manual shift lever and neutral start switch. Remove throttle cable bolt and plate. Remove solenoid wire bolt. See Fig 1 or Fig 2.
  3. On A-241H, remove governor cover bracket. Remove governor cover and "O" ring. Remove governor body, thrust washer, governor body adapter and gasket.
    CAUTION: DO NOT  turn transaxle over, as this will contaminate valve body with any foreign material that is trapped in the oil pan.
  4. On all models, remove oil pan bolts and oil pan. See Fig 3. Place transaxle on wooden blocks to prevent damage to pipe bracket. Examine particles found in oil pan. If particles are magnetic (steel), bearing, gear and clutch plate wear are indicated. If particles are non-magnetic (brass), bushing wear is indicated.
  5. Turn transaxle over. Remove tube bracket, oil strainer and solenoid connectors (if equipped). Using screwdriver, remove oil tubes.
  6. On all models, remove control valve assembly bolts. Disconnect throttle valve cable from cam. Remove control valve assembly. Remove throttle cable. Remove solenoid wiring from case (if equipped). Remove 2nd brake apply gasket.
  7. To remove accumulator pistons and springs, loosen 5 bolts one turn at a time until spring tension is released. Remove cover and gasket. Remove piston and spring for forward clutch.
  8. Using 14 psi (1 kg/cm2 ) of compressed air in apply hole, pop out direct clutch and 2nd brake accumulator pistons and springs into a shop cloth. See Fig 4.
  9. Using Wire Gauge Set (09240-00020), measure piston stroke of 2nd coast brake. On A-241H, piston stroke should be .059-.118" (1.5-3.0 mm). On all models, if piston stroke exceeds specification, inspect 2nd coast brake band.
  10. To remove 2nd coast brake band, remove snap ring and cover. Remove 2nd coast brake piston and outer return spring.
    Fig 1: Exploded View Of External Components (A-241H)
    G93F25739Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    Fig 2: Exploded View Of External Components (A-540E & A-540H)
    G93I25740Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    Fig 3: Exploded View Of Lower External Components (A-540E & A-540H Shown; A-241H Is Similar)
    G93J25741Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    Fig 4: Removing Accumulator Pistons & Springs
    G93A25742Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    NOTE: Before removing oil pump, remove 2nd coast brake piston.
  11. Remove oil pump-to-case bolts. Using Puller (09350-32014), pull oil pump from case. Remove direct clutch and forward clutch. Separate direct clutch and forward clutch. Remove thrust washer from direct clutch. Remove bearings from forward clutch. Push pin with a small screwdriver to remove pin from bolt hole of oil pump mounting, and remove 2nd coast brake band. See Fig 5.
  12. Remove front planetary ring gear. Remove front planetary gear. Remove 2 bearings from planetary gear. Remove sun gear and sun gear drum. Remove thrust washer from sun gear input drum. Check operation of 2nd brake piston by applying compressed air into case passage and confirming that piston moves. If piston does not move, disassemble and inspect. Remove 2nd coast brake band guide.
  13. Remove snap ring holding 2nd brake drum to case. Remove 2nd brake drum. If brake drum is difficult to remove, lightly tap drum with a wooden block. Remove 2nd brake piston return spring. Remove clutch plate, discs and flange. Remove 2nd brake drum gasket.
  14. Remove snap ring holding No. 2 one-way clutch outer race to case. Remove the No. 2 one-way clutch and rear planetary gear. On A-241H, remove thrust washer from rear planetary gear. Remove rear planetary ring gear, bearing and race.
  15. Check operation of 1st and reverse brake piston. Apply compressed air into case passage and confirm that piston moves. If piston does not move, disassemble and inspect.
    Fig 5: Exploded View Of Internal Components (A-540E & A-540H Shown; A-241H Is Similar)
    G93B25743Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    Fig 6: Checking 1st & Reverse Brake Pack Clearance
    G93C25744Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  16. Remove snap ring holding flange to case. Remove flange, discs and plates of 1st and reverse brake. Turn transaxle case around. Remove 13 bolts attaching overdrive case to transaxle.
  17. On A-241H, tap transaxle cover using a plastic hammer. Remove cover. Remove intermediate shaft. Remove snap ring. Using Spring Compressor (09351-32040), compress return spring until snap ring is free from spring seat. Remove snap ring. Remove spring compressor. Remove return spring from case. Apply compressed air into passage of case to remove piston. If piston does not pop out with compressed air, use needle-nose pliers to remove piston. Remove 2 "O" rings from piston. Remove transaxle housing-to-case bolts. Remove transaxle housing. Remove differential, governor driven gear and thrust washer.
  18. Remove apply gaskets. Measure countershaft end play. End play should be .0091-.0350" (.230-.890 mm).
  19. Using a chisel, release staked area of countershaft lock nuts. Using Holder (09330-00021) and Adapter (09351-32032), remove front and rear countershaft lock nuts. See Fig 7.
  20. Using Puller (09351-32061), remove counter driven gear. Remove thrust needle bearing. Remove countershaft assembly. Remove thrust bearing with race from countershaft. Remove underdrive clutch drum and anti-rattle clip. Using compressed air, confirm underdrive brake piston moves smoothly. Remove oil seal rings. See Fig 7.
  21. Using Spring Compressor (09351-32070) and arbor press, compress flange until snap ring is free from flange. Remove snap ring with a screwdriver. Remove flange, plates and discs. Note location of components. Remove underdrive brake return spring. Remove underdrive brake piston using compressed air. Remove 2 "O" rings from piston.
  22. Remove parking lock pawl stopper plate, torsion spring and spring guide. Remove pawl shaft clamp. Remove parking lock sleeve and cam guide bracket. Remove transaxle case plate. Remove manual valve shaft spacer and pin. Remove spring from manual valve shaft. Remove manual valve shaft, lever and washer. See Fig 1.
  23. Using screwdriver and hammer, remove manual shaft oil seal. Remove oil seal rings. Using a 14-mm socket and hammer, drive in new oil seal. Apply grease to oil seal lip.
  24. Remove oil galley cover and gasket. Remove underdrive brake accumulator piston and spring. See Fig 3 and Fig 4 . Using Puller (09308-00010), remove bearing from housing. Remove apply gasket from transaxle housing.
  25. Remove oil tube clamps. Using screwdriver, carefully remove oil tubes. Remove oil tube apply cover, gasket and strainer. Remove bearing bolt and stopper or retainer. Using Puller (09612-65014), remove bearing. Remove oil seal ring (if installed).
Fig 7: Exploded View Of Rear Components (A-241H)
G93D25745Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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