Automatic Transaxle Unit: Disassembly
- REMOVE SPEEDOMETER SENSOR
- Remove the bolt and remove the speedometer sensor.
- REMOVE SPEEDOMETER DRIVEN GEAR
- Remove the clip and speedometer driven gear from the speedometer sensor.
- Remove the O-ring from the speedometer sensor.
- REMOVE PARK/NEUTRAL POSITION SWITCH ASSEMBLY
- Remove the nut and washer and remove the control lever shaft.
- Using a screwdriver, pry out the lock plate and remove the manual valve shaft nut.
- Remove the 2 bolts and pull out the park/neutral position switch assembly.
- REMOVE TRANSMISSION REVOLUTION SENSOR
- Remove the bolt and remove the transmission revolution sensor.
- REMOVE OIL COOLER TUBE UNION
- Remove the 2 oil cooler tube unions from the transaxle case.
- Remove the 2 O-rings from the 2 oil cooler tube unions.
- REMOVE NO. 1 TRANSAXLE CASE PLUG
- Remove the 4 No. 1 transaxle case plugs from the transaxle housing and transaxle case.
- Remove the No. 1 transaxle case plug from the transaxle case.
- Remove the O-rings from the No. 1 transaxle case plugs.
- REMOVE BREATHER PLUG HOSE
- Remove the breather plug hose from the transaxle case.
- FIX AUTOMATIC TRANSAXLE ASSEMBLY
- REMOVE AUTOMATIC TRANSAXLE OIL PAN SUBASSEMBLY
- Remove the 19 bolts and remove the oil pan and oil pan gasket.
- Remove the 2 oil cleaner magnets from the oil pan.
- Examine the particles in the pan.
- Collect any steel chips with the removed magnets.
Carefully look at the foreign matter and particles in the pan and on the magnets to predict the type of wear which might be found in the transaxle.
Steel (magnetic): bearing, gear and clutch plate wear
Brass (non-magnetic): bearing wear
- Collect any steel chips with the removed magnets.
- REMOVE VALVE BODY OIL STRAINER ASSEMBLY
- Remove the 3 bolts and remove the oil strainer assembly.
- Remove the oil strainer gasket from the oil strainer.
- REMOVE TRANSMISSION VALVE BODY ASSEMBLY
- Disconnect the 5 solenoid connectors.
- Remove the bolt and lock plate and remove the ATF temperature sensor.
- Remove the 2 bolts and remove the detent spring cover and detent spring.
- Remove the 13 bolts and the valve body assembly from the transaxle case.
- REMOVE TRANSMISSION WIRE
- Remove the bolt and the transmission wire from the transaxle case.
- Remove the O-ring from the transmission wire.
- REMOVE TRANSAXLE CASE 2ND BRAKE GASKET
- Remove the transaxle case 2nd brake gasket from the transaxle case.
- REMOVE TRANSAXLE CASE GASKET
- Remove the transaxle case gasket from the transaxle case.
- REMOVE BRAKE DRUM GASKET
- Remove the brake drum gasket from the transaxle case.
- REMOVE CHECK BALL BODY
- Remove the check ball body and spring from the transaxle case.
- REMOVE B-2 ACCUMULATOR PISTON
- Apply compressed air (392 kPa, 4.0 kgf/cm2 , 57 psi) to the oil hole and remove the B-2 accumulator piston and spring.
- Remove the 2 O-rings from the B-2 accumulator piston.
- REMOVE C-3 ACCUMULATOR PISTON
- Apply compressed air (392 kPa, 4.0 kgf/cm2 , 57 psi) to the oil hole and remove the C-3 accumulator piston and spring.
- Remove the 2 O-rings from the C-3 accumulator piston.
- REMOVE C-2 ACCUMULATOR PISTON
- Apply compressed air (392 kPa, 4.0 kgf/cm2 , 57 psi) to the oil hole and remove the C-2 accumulator piston and the spring.
- Remove the 2 O-rings from the C-2 accumulator piston.
- REMOVE TRANSAXLE HOUSING
- Remove the 14 bolts.
- Tap around the circumference of the transaxle housing with a plastic hammer to remove the transaxle housing from the transaxle case.NOTE: The differential gear assembly may be accidentally removed when the transaxle housing is removed.
- INSPECT INPUT SHAFT END PLAY
- Measure the end play in the axial direction.
End play:
0.37 to 1.29 mm (0.0146 to 0.0508 in.)
If the end play is not as specified, select and replace the thrust needle roller bearing.
- Measure the end play in the axial direction.
- REMOVE OIL PUMP ASSEMBLY
- Remove the 7 bolts and the oil pump assembly from the transaxle case.
- REMOVE DIFFERENTIAL GEAR ASSEMBLY
- Remove the differential gear assembly from the transaxle case.
- REMOVE OVERDRIVE BRAKE GASKET
- Using a screwdriver, remove the 2 overdrive brake gaskets from the transaxle case.
- REMOVE INPUT SHAFT ASSEMBLY
- Remove the input shaft assembly from the transaxle case.
- REMOVE STATOR SHAFT THRUST NEEDLE ROLLER BEARING
- Remove the thrust needle roller bearing from the input shaft.
- REMOVE FORWARD CLUTCH HUB THRUST NEEDLE ROLLER BEARING
- Remove the thrust needle roller bearing from the forward clutch hub.
- INSPECT INTERMEDIATE SHAFT ASSEMBLY
- Using a dial indicator, measure the clearance of the intermediate shaft.
Standard clearance:
0.204 to 0.966 mm (0.008 to 0.038 in.)
- Using a dial indicator, measure the clearance of the intermediate shaft.
- REMOVE FORWARD CLUTCH HUB SUB-ASSEMBLY
- Remove the forward clutch hub from the transaxle case.
- REMOVE REAR TRANSAXLE COVER ASSEMBLY
- Remove the 11 bolts.
- Tap around the circumference of the rear transaxle cover with a plastic hammer to remove the rear transaxle cover from the transaxle case.
- REMOVE TRANSAXLE CASE GASKET
- Remove the 4 transaxle case gaskets.
- REMOVE REAR CLUTCH DRUM THRUST NEEDLE ROLLER BEARING
- Using a magnetic finger, remove the thrust needle roller bearing.
- REMOVE INTERMEDIATE SHAFT ASSEMBLY
- Remove the intermediate shaft assembly from the transaxle case.
- REMOVE 2ND COAST AND OVERDRIVE BRAKE DISC
- Remove the flange, 2 discs and 2 No. 2 flanges from the transaxle.
- REMOVE THRUST NEEDLE ROLLER BEARING
- Using a magnetic finger, remove the C-2 hub thrust bearing race, the thrust needle roller bearing and the thrust bearing race from the direct clutch hub.
- REMOVE DIRECT CLUTCH HUB
- Remove the direct clutch hub from the transaxle case.
- REMOVE REAR NO. 2 PLANETARY SUN GEAR THRUST NEEDLE ROLLER BEARING
- Using a magnetic finger, remove the thrust bearing from the rear thrust needle bearing.
- REMOVE REAR PLANETARY SUN GEAR ASSEMBLY
- Remove the rear planetary sun gear from the transaxle case.
- REMOVE REAR PLANETARY SUN GEAR THRUST NEEDLE ROLLER BEARING
- Remove the rear planetary sun gear thrust needle roller bearing and thrust washer No. 1 from the rear planetary sun gear.
- INSPECT 1-WAY CLUTCH ASSEMBLY
- Hold the rear planetary sun gear and turn the 1-way clutch.
- Make sure that 1 -way clutch turns freely counterclockwise and locks when turned clockwise.
- REMOVE 1-WAY CLUTCH ASSEMBLY
- Remove the 1-way clutch assembly and planetary carrier thrust washer No. 2 from the rear planetary sun gear.
- REMOVE 2ND COAST AND OVERDRIVE BRAKE FLANGE HOLE SNAP RING
- Using a screwdriver, remove the snap ring from the transaxle case.
- REMOVE 2ND BRAKE BRAKE DISC
- Using a screwdriver, remove the snap ring.
- Remove the flange, 3 discs and 3 plates from the transaxle.
- REMOVE 2ND BRAKE PISTON SLEEVE
- Remove the 2nd brake piston sleeve from the transaxle case.
- INSPECT NO. 2 1-WAY CLUTCH
- Install the 1-way clutch and the thrust washer onto the rear planetary sun gear.
- Hold the rear planetary sun gear and turn the 1 -way clutch.
- Make sure that the 1 -way clutch turns freely counterclockwise and locks when turned clockwise.
- REMOVE REAR PLANETARY GEAR ASSEMBLY
- Using a screwdriver, remove the snap ring.
- Remove the rear planetary gear assembly from the transaxle case.
- REMOVE REAR PLANETARY GEAR THRUST NEEDLE ROLLER BEARING
- Remove the thrust needle roller bearing and 2 bearing races from the rear planetary gear assembly.
- REMOVE NO. 2 1-WAY CLUTCH
- Separate the 2nd brake cylinder, 1-way clutch No. and the rear planetary gear.
- REMOVE OUTER RACE RETAINER
- Remove the retainer from 1-way clutch No. 2.
- REMOVE FRONT PLANETARY SUN GEAR
- Remove the front planetary sun gear and thrust needle roller bearing from the transaxle case.
- REMOVE 1ST AND REVERSE BRAKE DISC
- Using a screwdriver, remove the snap ring.
- Remove the flange, 4 discs and 4 plates from the transaxle case.
- REMOVE 1ST AND REVERSE BRAKE RETURN SPRING SUB-ASSEMBLY
- Using SST, a press and a screwdriver, remove the snap ring.
SST 09387-00070
- Remove the 1st and reverse brake return spring sub-assembly.
- Using SST, a press and a screwdriver, remove the snap ring.
- REMOVE NO. 2 1ST AND REVERSE BRAKE PISTON
- Apply compressed air (392 kPa, 4.0 kgf/cm2 , 57 psi) to the transaxle case to remove the 1st and reverse brake piston.
- REMOVE NO. 2 1ST AND REVERSE BRAKE PISTON O-RING
- Remove the 2 O-rings from No. 2 1st and reverse brake piston.
- REMOVE COUNTER DRIVE GEAR NUT
- Fix the counter driven gear with the parking lock pawl.
- Using SST and a hammer, release the lock washer.
SST 09930-00010
- Using SST, remove the nut and lock washer.
SST 09387-00120
- REMOVE PLANETARY GEAR ASSEMBLY
- Using SST and a press, remove the planetary gear assembly from the transaxle case.
SST 09950-60010 (09951 -00400, 09951 -00320, 09952-06010), 09950-70010 (09951-07100)
- Using SST and a press, remove the planetary gear assembly from the transaxle case.
- REMOVE COUNTER DRIVE GEAR
- Install the 2 bolts onto the counter drive gear.
Bolt (M6):
L = 40 to 80 mm
Pitch = 1.0 mm
- Rotate the 2 bolts and remove the counter drive gear and front planetary sun gear.
- Remove the 2 radial ball bearings from the counter drive gear and front planetary sun gear.
- Install the 2 bolts onto the counter drive gear.
- REMOVE PARKING LOCK PAWL BRACKET
- Remove the 3 bolts, cam guide and bracket from the transaxle case.
- REMOVE MANUAL VALVE LEVER SHAFT RETAINER SPRING
- Remove the manual valve lever shaft retainer spring from the manual valve lever shaft.
- REMOVE MANUAL VALVE LEVER SUB-ASSEMBLY
- Using a screwdriver, release and remove the spacer.
- Using a pin punch and hammer, drive out the manual valve lever shaft spring pin.
- Remove the manual valve lever shaft and manual valve lever.
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
- REMOVE PARKING LOCK ROD SUB-ASSEMBLY
- Remove the parking lock rod from the manual valve lever.
- REMOVE MANUAL VALVE LEVER SHAFT
- Remove the manual valve lever shaft from the transaxle case.
- REMOVE PARKING LOCK PAWL
- Using a screwdriver, remove the parking lock pawl shaft from the transaxle case.
- Remove the parking lock pawl torsion spring and parking lock pawl from the transaxle case.
- REMOVE COUNTER DRIVEN GEAR
- Remove the counter driven gear, drive pinion and thrust needle roller bearing from the transaxle case.
- REMOVE DIFFERENTIAL DRIVE PINION PLUG
- Using a brass bar and a hammer, remove the differential drive pinion plug.
- REMOVE DIFFERENTIAL DRIVE PINION
- Using SST and a press, remove the differential drive pinion from the counter driven gear.
SST 09950-60010 (09951 -00350), 09950-70010 (09951-07150)
- Using SST and a press, remove the differential drive pinion from the counter driven gear.
- REMOVE BEARING LOCK PLATE
- Remove the bolt and remove the bearing lock plate.
- REMOVE DIFFERENTIAL GEAR LUBE APPLY TUBE
- Remove the differential gear lube apply tube from the transaxle housing.
- REMOVE FRONT DRIVE PINION FRONT TAPERED ROLLER BEARING
- Using SST, remove the front drive pinion front tapered roller bearing from the transaxle housing.
SST 09308-10010
- Using SST, remove the front drive pinion front tapered roller bearing from the transaxle housing.
- REMOVE FRONT DRIVE PINION REAR TAPERED ROLLER BEARING
- Using SST, remove the front drive pinion rear tapered roller bearing from the transaxle case.
SST 09612-65014 (09612-01040)
- Remove transaxle case plate No. 1 from the transaxle case.
- Using SST, remove the front drive pinion rear tapered roller bearing from the transaxle case.
- REMOVE COUNTER DRIVE GEAR BEARING
- Remove the 2 counter drive gear bearing inner races RH from the transaxle case.
- Using SST, remove the counter drive gear bearing LH outer race from the transaxle case.
SST 09308-00010
- Using SST, remove the counter drive gear bearing rear outer race from the transaxle case.
SST 09308-00010
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
- REMOVE COUNTER DRIVE GEAR HOLE SNAP RING
- Using a screwdriver, remove the counter drive gear hole snap ring from the transaxle case.
- REMOVE MANUAL VALVE LEVER SHAFT OIL SEAL
- Using a screwdriver, remove the oil seal from the transaxle case.
- REMOVE FRONT TRANSAXLE CASE OIL SEAL
- Using SST and a hammer, remove the oil seal from the transaxle case.
SST 09950-60010 (09951 -00550), 09950-70010 (09951-07100)
- Using SST and a hammer, remove the oil seal from the transaxle case.
- REMOVE TRANSAXLE CASE OIL SEAL
- Using SST and a hammer, remove the transaxle case oil seal from the transaxle housing.
SST 09950-60010 (09951 -00530), 09950-70010 (09951-07100)
- Using SST and a hammer, remove the transaxle case oil seal from the transaxle housing.