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Automatic Transaxle Unit: Disassembly

WARNING: This page is about a different variant/trim than selected.
  1. REMOVE PARK/NEUTRAL POSITION SWITCH ASSEMBLY 
    1. Remove the nut, washer and control shaft lever.
      Fig 1: Locating Nut And Control Shaft Lever With Washer
      G06011613Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using a screwdriver, unstake the lock plate, and remove the lock nut and nut stopper.
      Fig 2: Staking Nut With Lock Plate
      G04975926Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Remove the 2 bolts and pull out the park/neutral position switch.
      Fig 3: Locating Bolts And Park/Neutral Position Switch
      G04975931Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  2. REMOVE NO. 2 BREATHER PLUG 
    1. Remove the No. 2 breather plug from the transaxle case.
      Fig 4: Locating No 2 Breather Plug From Transaxle Case
      G04976088Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the hose and O-ring from the No. 2 breather plug.
      Fig 5: Identifying O-Ring And No 2 Breather Plug
      G04976089Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  3. REMOVE OIL COOLER TUBE ELBOW (INLET OIL COOLER ELBOW) 
    1. Remove the elbow.
    2. Remove the O-ring from the elbow.
      Fig 6: Removing Oil Cooler Tube Elbow
      G06011618Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  4. REMOVE OIL COOLER TUBE UNION (OUTLET OIL COOLER UNION) 
    1. Remove the union.
    2. Remove the O-ring from the union.
      Fig 7: Identifying Oil Cooler Tube Union
      G06011619Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  5. REMOVE SPEED SENSOR 
    1. Remove the 2 bolts and the 2 speed sensors from the transaxle assembly.
    2. Remove the 2 O-rings from the 2 speed sensors.
      Fig 8: Identifying O-Rings From Speed Sensors
      G06011620Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  6. REMOVE NO. 1 TRANSAXLE CASE PLUG 
    1. Remove the 4 No. 1 transaxle case plugs from the transaxle case.
    2. Remove the O-ring from each No. 1 transaxle case plug.
      Fig 9: Identifying No 1 Transaxle Case Plug
      G06011621Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  7. SECURE AUTOMATIC TRANSAXLE ASSEMBLY 
    1. Secure the transaxle assembly onto wooden blocks.
  8. REMOVE AUTOMATIC TRANSAXLE OIL PAN SUB-ASSEMBLY 
    1. Remove the drain plug and drain plug gasket from the oil pan.
      Fig 10: Identifying Automatic Transaxle Oil Pan Sub-Assembly
      G04976094Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the 18 bolts, oil pan and gasket.
      Fig 11: Locating Bolts And Oil Pan Gasket
      G04975941Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Remove the 2 transmission oil cleaner magnets from the oil pan.
      Fig 12: Identifying Transmission Oil Cleaner Magnets From Oil Pan
      G04976096Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  9. INSPECT TRANSMISSION OIL CLEANER MAGNET 
    1. Remove the magnets and use them to collect any steel chips. Examine the chips and particles in the pan and on the magnet to determine what type of wear has occurred in the transaxle.

      Result: 

      Steel (magnetic): bearing, gear, and plate wear 

      Brass (non-magnetic): bushing wear 

      Fig 13: [Removing Magnets]
      G04976097Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  10. DISCONNECT TRANSMISSION WIRE 
    1. Disconnect the 7 connectors from the shift solenoid valves.
    2. Remove the bolt, lock plate, and ATF temperature sensor.
      Fig 14: Locating Connectors From Shift Solenoid Valves
      G06011626Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  11. REMOVE TRANSMISSION WIRE 
    1. Remove the bolt and transmission wire from the transaxle case.
      Fig 15: Identifying Transmission Wire
      G04976099Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  12. REMOVE VALVE BODY OIL STRAINER ASSEMBLY 
    1. Remove the 3 bolts and oil strainer.
      Fig 16: Locating Bolts And Oil Strainer
      G04976100Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the O-ring from the oil strainer.
      Fig 17: Locating O-Ring From Oil Strainer
      G04976101Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  13. REMOVE TRANSMISSION VALVE BODY ASSEMBLY 
    1. Support the valve body assembly and remove the 17 bolts and valve body assembly.
      Fig 18: Locating Bolts And Valve Body Assembly
      G04975959Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  14. REMOVE NO. 1 GOVERNOR APPLY GASKET 
    1. Remove the No. 1 governor apply gasket from the transaxle case.
      Fig 19: Locating No 1 Governor Apply Gasket
      G04976103Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  15. REMOVE TRANSAXLE CASE 2ND BRAKE GASKET 
    1. Remove the transaxle case 2nd brake gasket from the transaxle case.
      Fig 20: Identifying Transaxle Case 2nd Brake Gasket
      G04976104Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  16. REMOVE BRAKE DRUM GASKET 
    1. Remove the brake drum gasket from the transaxle case.
      Fig 21: Identifying Brake Drum Gasket
      G04976105Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  17. REMOVE CHECK BALL BODY 
    1. Remove the check ball body and spring from the transaxle case.
      Fig 22: Identifying Check Ball Body And Spring
      G04976106Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  18. REMOVE C-3 ACCUMULATOR PISTON 
    1. Remove the spring from the C-3 accumulator piston.
      Fig 23: Identifying Spring From C-3 Accumulator Piston
      G04976107Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using needle-nose pliers, remove the C-3 accumulator piston from the transaxle case.
      Fig 24: Removing C-3 Accumulator Piston From Transaxle Case
      G06011636Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Remove the O-ring from the C-3 accumulator piston.
      Fig 25: Identifying O-Ring From C-3 Accumulator Piston
      G06011637Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  19. REMOVE REVERSE CLUTCH ACCUMULATOR PISTON 
    1. Apply compressed air (392 kPa, 4.0 kgf/cm2 , 57 psi) to the oil hole and remove the reverse accumulator piston and spring.
      NOTE:
      • Applying compressed air may cause the piston to jump out. When removing the piston, hold it by hand using a piece of cloth.
      • Take care not to splash ATF when applying compressed air.
      Fig 26: Removing Reverse Clutch Accumulator Piston
      G06011638Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the 2 O-rings from the reverse clutch accumulator piston.
      Fig 27: Identifying O-Rings From Reverse Clutch Accumulator Piston
      G04976111Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  20. REMOVE B-3 ACCUMULATOR PISTON 
    1. Apply compressed air (392 kPa, 4.0 kgf/cm2 , 57 psi) to the oil hole and remove the B-3 accumulator piston and 2 springs.
      NOTE:
      • Applying compressed air may cause the piston to jump out. When removing the piston, hold it by hand using a piece of cloth.
      • Take care not to splash ATF when applying compressed air.
      Fig 28: Removing B-3 Accumulator Piston
      G04976112Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the O-ring from the B-3 accumulator piston.
      Fig 29: Identifying O-Ring From B-3 Accumulator Piston
      G06011641Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  21. REMOVE MANUAL VALVE LEVER SHAFT RETAINER SPRING 
    1. Using needle-nose pliers, remove the manual valve lever shaft retainer spring.
      Fig 30: Removing Manual Valve Lever Shaft Retainer Spring
      G04976114Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  22. REMOVE MANUAL DETENT SPRING SUB-ASSEMBLY 
    1. Remove the 2 bolts and manual detent spring sub-assembly.
      Fig 31: Locating Bolts And Manual Detent Spring Sub-Assembly
      G05000754Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  23. REMOVE PARKING LOCK PAWL BRACKET 
    1. Remove the 2 bolts and parking lock pawl bracket.
      Fig 32: Locating Bolts And Parking Lock Pawl Bracket
      G04976116Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  24. REMOVE MANUAL VALVE LEVER SUB-ASSEMBLY 
    1. Using a screwdriver, slide the spacer.
      Fig 33: Removing Manual Valve Lever Sub-Assembly
      G04976117Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using a pin punch (3mm) and hammer, drive out the pin.

      HINT:

      Slowly drive out the pin so that it will not fall into the transaxle case.

      Fig 34: Driving Out Pin
      G04976118Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Remove the manual valve lever shaft, manual valve lever and spacer.
      Fig 35: Removing Parking Lock Rod Sub-Assembly
      G04976119Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  25. REMOVE PARKING LOCK ROD SUB-ASSEMBLY 
    1. Remove the parking lock rod sub-assembly from the manual valve lever sub-assembly.

      HINT:

      Align the dial with the notches on the manual valve lever sub-assembly to remove the parking lock rod sub-assembly.

      Fig 36: Identifying Parking Lock Rod Sub-Assembly
      G06011648Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  26. REMOVE MANUAL VALVE LEVER SHAFT OIL SEAL 
    1. Using a screwdriver, remove the oil seal from the transaxle case.
  27. SECURE AUTOMATIC TRANSAXLE ASSEMBLY 
    1. Secure the transaxle case with the oil pump facing up.
  28. INSPECT INPUT SHAFT END PLAY  (See INSPECTION )
    Fig 37: Inspecting Input Shaft End Play
    G04976121Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  29. REMOVE TRANSAXLE HOUSING 
    1. Remove the 18 bolts.
    2. Tap on the circumference of the transaxle housing with a plastic hammer to remove the transaxle housing from the transaxle case.
      NOTE: The differential may be accidentally removed when the transaxle housing is removed.
      Fig 38: Locating Bolts And Transaxle Housing
      G06011650Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  30. REMOVE OIL PUMP ASSEMBLY 
    1. Remove the 7 bolts and oil pump from the transaxle case.
      Fig 39: Locating Bolts And Oil Pump From Transaxle Case
      G04976123Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  31. REMOVE THRUST NEEDLE ROLLER BEARING 
    1. Remove the thrust needle roller bearing from the underdrive planetary gear assembly.
      Fig 40: Identifying Thrust Needle Roller Bearing
      G06011652Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  32. REMOVE NO. 2 THRUST BEARING UNDERDRIVE RACE 
    1. Remove the No. 2 thrust bearing underdrive race from the underdrive planetary gear assembly.
      Fig 41: Identifying No 2 Thrust Bearing Underdrive Race
      G06011653Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  33. REMOVE DIFFERENTIAL GEAR ASSEMBLY 
    1. Remove the differential gear assembly from the transaxle case.
      Fig 42: Identifying Differential Gear Assembly
      G06011654Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  34. REMOVE OVERDRIVE BRAKE GASKET 
    1. Remove the 2 overdrive brake gaskets from the transaxle case.
      Fig 43: Identifying Overdrive Brake Gasket
      G04976127Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  35. REMOVE FORWARD CLUTCH ASSEMBLY 
    1. Remove the forward clutch assembly from the transaxle case.
      Fig 44: Identifying Forward Clutch Assembly
      G06011656Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the thrust needle roller bearing from the forward clutch.
  36. INSPECT PACK CLEARANCE OF FORWARD CLUTCH  (See INSPECTION )
    Fig 45: Identifying Thrust Needle Roller Bearing
    G04976129Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  37. REMOVE FORWARD MULTIPLE DISC CLUTCH DISC 
    1. Using a screwdriver, remove the snap ring.
      Fig 46: Identifying Snap Ring
      G04976375Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the flange, 5 discs and 5 plates from the input shaft assembly.
      Fig 47: Identifying Discs And Plates From Input Shaft Assembly
      G04976376Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  38. REMOVE FORWARD CLUTCH RETURN SPRING SUB-ASSEMBLY 
    1. Place SST on the spring retainer and compress the return spring with a press.

      SST 09387-00020 

    2. Using a snap ring expander, remove the snap ring.
      NOTE:
      • Stop the press when the spring seat is lowered 1 to 2 mm (0.0393 to 0.0787 in.) from the snap ring groove. This prevents the spring seat from being deformed.
        Fig 48: Removing Snap Ring
        G04976377Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      • Do not expand the snap ring excessively.
    3. Remove the clutch balancer from the input shaft.
      Fig 49: Identifying Clutch Balancer From Input Shaft
      G04976378Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Remove the forward clutch return spring from the input shaft.
      Fig 50: Identifying Forward Clutch Return Spring From Input Shaft
      G04976379Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  39. REMOVE FORWARD CLUTCH PISTON SUB-ASSEMBLY 
    1. Place the forward clutch drum onto the oil pump.
    2. Holding the forward clutch piston by hand, apply compressed air (392 kPa, 4.0 kgf/cm2 , 57 psi) to the oil pump to remove the forward clutch piston.

      HINT:

      If the piston is slanted and cannot be removed, either blow air again with the protruding side pushed, or remove the piston using needle nose pliers with the tips taped.

      Fig 51: Removing Forward Clutch Piston Sub-Assembly
      G04976380Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  40. REMOVE INPUT SHAFT OIL SEAL RING 
    1. Remove the input shaft oil seal ring from the input shaft.
      Fig 52: Removing Input Shaft Oil Seal Ring
      G04976381Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  41. REMOVE MULTIPLE DISC CLUTCH HUB 
    1. Remove the thrust needle roller bearing, multiple disc clutch hub, thrust needle roller bearing and No. 1 thrust bearing race from the transaxle case.
  42. INSPECT MULTIPLE DISC CLUTCH HUB  (See INSPECTION )
    Fig 53: Identifying Thrust Needle Roller Bearing And Multiple Disc Clutch Hub
    G06011665Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  43. REMOVE UNDERDRIVE PLANETARY GEAR ASSEMBLY 
    1. Remove the bolt and pawl shaft clamp from the transaxle case.
      Fig 54: Identifying Pawl Shaft Clamp And Bolt
      G06011666Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the parking lock pawl shaft from the transaxle case.
      Fig 55: Removing Parking Lock Pawl Shaft From Transaxle Case
      G05000771Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Push the parking lock pawl.

      HINT:

      Failure to do so will cause interference when the underdrive planetary gear is removed.

      Fig 56: Pushing Parking Lock Pawl
      G04976133Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Remove the underdrive planetary gear assembly from the transaxle case.
      NOTE: Do not drop the underdrive planetary gear assembly.
      Fig 57: Removing Underdrive Planetary Gear Assembly From Transaxle Case
      G06011669Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  44. REMOVE FRONT PLANETARY GEAR NUT 
    1. Using SST and a hammer, loosen the staked part of the gear nut.

      SST 09930-00010 (09931 -00010, 09931 -00020), 09387-00050, 09495-65040 

      Fig 58: Removing Front Planetary Gear Nut
      G04976395Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Clamp the underdrive planetary gear in a soft jaw vise.
      NOTE: Be careful not to damage the differential drive pinion.
      Fig 59: Identifying Underdrive Planetary Gear
      G04976396Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Using a socket wrench, remove the gear nut.
      Fig 60: Removing Gear Nut
      G04976397Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  45. REMOVE CYLINDRICAL ROLLER BEARING RACE INNER 
    1. Using SST, remove the cylindrical roller bearing race inner.

      SST 09950-00020, 09950-00030, 09950-40011 (09957-04010), 09950-60010 (09951-00320) 

      Fig 61: Removing Cylindrical Roller Bearing Race Inner
      G05001042Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  46. REMOVE UNDERDRIVE PLANETARY GEAR ASSEMBLY 
    1. Using SST and a press, remove the differential drive pinion, parking lock gear, counter driven gear with underdrive planetary ring gear, and angular ball bearing.

      SST 09387-00050, 09495-65040, 09950-60010 (09951-00320), 09950-70010 (09951-07100) 

      Fig 62: Removing Underdrive Planetary Gear Assembly
      G04976399Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Clamp the underdrive planetary gear in a soft jaw vise.
    3. Using SST, remove the rear angular ball bearing from the underdrive planetary gear.

      SST 09950-00020, 09950-00030, 09950-40011 (09957-04010), 09950-60010 (09951-00320) 

      Fig 63: Removing Rear Angular Ball Bearing From Underdrive Planetary Gear
      G05559571Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  47. REMOVE UNDERDRIVE PLANETARY RING GEAR 
    1. Using snap ring pliers, remove the snap ring.
      Fig 64: Removing Snap Ring
      G04976401Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the underdrive planetary ring gear from the counter driven gear.
      Fig 65: Identifying Underdrive Planetary Ring Gear From Counter Driven Gear
      G04976402Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  48. REMOVE PARKING LOCK PAWL 
    1. Remove the spring, pawl pin and parking lock pawl.
      Fig 66: Identifying Parking Lock Pawl
      G05000774Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  49. REMOVE UNDERDRIVE CLUTCH ASSEMBLY 
    1. Remove the underdrive clutch assembly, thrust bearing, and bearing race from the transaxle case.
      Fig 67: Identifying Underdrive Clutch Assembly
      G05559307Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  50. REMOVE NO. 2 UNDERDRIVE CLUTCH FLANGE HOLE SNAP RING 
    1. Using a screwdriver, remove the No. 2 underdrive clutch flange hole snap ring.
      Fig 68: Removing No 2 Underdrive Clutch Flange Hole Snap Ring
      G04976419Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  51. REMOVE NO. 1 UNDERDRIVE CLUTCH DISC 
    1. Remove the flange, 3 discs, and 3 plates from the underdrive clutch drum.
      Fig 69: Identifying Discs And Plates From Underdrive Clutch Drum
      G04976420Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  52. REMOVE UNDERDRIVE CLUTCH RETURN SPRING SUB-ASSEMBLY 
    1. Place SST on the clutch balancer and compress the spring with a press.

      SST 09350-32014 (09351 -32070) 

    2. Using a snap ring expander, remove the snap ring.
      NOTE:
      • Stop the press when the spring seat is lowered 1 to 2 mm (0.0393 to 0.0787 in.) from the snap ring groove. This prevents the spring seat from being deformed.
        Fig 70: Removing Snap Ring
        G04976421Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      • Do not expand the snap ring excessively.
    3. Remove the clutch balancer from the underdrive clutch drum.
      Fig 71: Removing Clutch Balancer From Underdrive Clutch Drum
      G04976422Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Remove the return spring from the underdrive clutch drum.
      Fig 72: Removing Return Spring From Underdrive Clutch Drum
      G06011684Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  53. REMOVE UNDERDRIVE CLUTCH PISTON SET 
    1. Remove the underdrive clutch from the transaxle case.
      NOTE: Be careful not to damage the oil seal ring.
    2. Holding the underdrive clutch piston by hand, apply compressed air (392 kPa, 4.0 kgf/cm2 , 57 psi) to the transaxle case to remove the underdrive clutch piston.
      Fig 73: Applying Compressed Air To Transaxle Case
      G05001068Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  54. REMOVE UNDERDRIVE CLUTCH DRUM O-RING 
    1. Using a screwdriver, remove the O-ring from the underdrive clutch drum.
      Fig 74: Removing O-Ring From Underdrive Clutch Drum
      G04976430Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  55. REMOVE UNDERDRIVE ONE-WAY CLUTCH ASSEMBLY 
    1. Using a screwdriver, remove the snap ring from the transaxle case.
      Fig 75: Removing Snap Ring From Transaxle Case
      G04976137Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the underdrive one-way clutch from the transaxle case.
      Fig 76: Identifying Underdrive One-Way Clutch From Transaxle Case
      G06011688Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Remove the outer race retainer from the one-way clutch.
      Fig 77: Identifying Outer Race Retainer From One-Way Clutch
      G04976139Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  56. REMOVE NO. 2 UNDERDRIVE CLUTCH DISC 
    1. Using a screwdriver, remove the snap ring.
      Fig 78: Identifying Snap Ring
      G04976140Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the flange, 3 discs and 3 plates from the transaxle case.
  57. INSPECT NO. 2 UNDERDRIVE CLUTCH DISC  (See INSPECTION )
    Fig 79: Identifying Discs And Plates From Transaxle Case
    G04976141Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  58. REMOVE TRANSAXLE REAR COVER SUB-ASSEMBLY 
    1. Remove the 11 bolts.
    2. Tap on the circumference of the rear cover with a plastic hammer to remove the transaxle rear cover from the transaxle case.
      Fig 80: Locating Bolts And Transaxle Rear Cover Sub-Assembly
      G06011692Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  59. REMOVE NO. 1 TRANSAXLE CASE PLUG 
    1. Remove the 4 No. 1 transaxle case plugs from the transaxle rear cover.
    2. Remove the O-ring from each No. 1 transaxle case plug.
      Fig 81: Identifying O-Ring From No 1 Transaxle Case Plug
      G06011693Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  60. REMOVE REAR CLUTCH OIL SEAL RING 
    1. Remove the 3 rear clutch oil seal rings from the transaxle rear cover.
      Fig 82: Identifying Rear Clutch Oil Seal Rings
      G06011694Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  61. REMOVE NEEDLE ROLLER BEARING 
    1. Using SST, remove the needle roller bearing from the transaxle rear cover.

      SST 09387-00041 (09387-01021, 09387-01030, 09387-01040) 

      Fig 83: Removing Needle Roller Bearing
      G04976145Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  62. REMOVE NO. 1 GOVERNOR APPLY GASKET 
    1. Using a screwdriver, remove the 3 apply gaskets.
      Fig 84: Locating No 1 Governor Apply Gasket
      G04976282Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  63. REMOVE BRAKE APPLY TUBE 
    1. Remove the bolt, clamp and brake apply tube.
    2. Remove the clutch apply tube.
    3. Remove the brake apply tube from the clamp.
      Fig 85: Locating Bolt And Brake Apply Tube
      G06011697Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  64. REMOVE DIRECT CLUTCH ASSEMBLY 
    1. Remove the thrust bearing and the direct clutch assembly from the transaxle case.
  65. INSPECT PACK CLEARANCE OF DIRECT CLUTCH  (See INSPECTION )
  66. INSPECT PACK CLEARANCE OF OVERDRIVE CLUTCH  (See INSPECTION )
    Fig 86: Identifying Thrust Bearing And Direct Clutch Assembly
    G06011698Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  67. REMOVE DIRECT MULTIPLE DISC CLUTCH DISC 
    1. Using a screwdriver, remove the snap ring from the intermediate shaft.
      Fig 87: Removing Snap Ring From Intermediate Shaft
      G06011699Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the flange, 3 discs, 3 plates and cushion plate from the intermediate shaft.
  68. INSPECT DIRECT MULTIPLE DISC CLUTCH DISC  (See INSPECTION )
    Fig 88: Identifying Discs And Plates Cushion Plate From Intermediate Shaft
    G04976150Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  69. REMOVE OVERDRIVE DIRECT CLUTCH DISC 
    1. Using a screwdriver, remove the snap ring from the intermediate shaft.
    2. Remove the flange, 3 discs and 3 plates from the intermediate shaft.
  70. INSPECT OVERDRIVE DIRECT CLUTCH DISC  (See INSPECTION )
    Fig 89: Identifying Discs And Plates From Intermediate Shaft
    G04976151Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  71. REMOVE OVERDRIVE CLUTCH RETURN SPRING SUB-ASSEMBLY 
    1. Place SST on the clutch balancer and compress the spring with a press.

      SST 09387-00020 

    2. Using a snap ring expander, remove the snap ring from the direct clutch drum.
      NOTE:
      • Stop the press when the spring seat is lowered 1 to 2 mm (0.0393 to 0.0787 in.) from the snap ring groove. This prevents the spring seat from being deformed.
      • Do not expand the snap ring excessively.
      Fig 90: Removing Snap Ring From Direct Clutch Drum
      G04976152Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Remove the clutch balancer from the overdrive direct clutch drum.
      Fig 91: Identifying Clutch Balancer From Overdrive Direct Clutch Drum
      G06011703Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Remove the overdrive clutch return spring from the overdrive direct clutch drum.
  72. INSPECT OVERDRIVE CLUTCH RETURN SPRING SUB-ASSEMBLY  (See INSPECTION )
    Fig 92: Identifying Overdrive Clutch Return Spring From Overdrive Direct Clutch Drum
    G04976154Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  73. REMOVE OVERDRIVE DIRECT CLUTCH PISTON 
    1. Install the intermediate shaft on the transaxle rear cover.
    2. Holding the direct clutch piston by hand, apply compressed air (392 kPa, 4.0 kgf/cm2 , 57 psi) to the transaxle rear cover to remove the direct clutch piston.
      Fig 93: Applying Compressed Air To Transaxle Rear Cover
      G04976155Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  74. REMOVE OVERDRIVE DIRECT CLUTCH DRUM SUB-ASSEMBLY 
    1. Holding the direct clutch drum by hand, apply compressed air (392 kPa, 4.0 kgf/cm2 , 57 psi) to the transaxle rear cover to remove the direct clutch drum.
      Fig 94: Applying Compressed Air To Transaxle Rear Cover
      G04976156Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  75. REMOVE OVERDRIVE DIRECT CLUTCH O-RING 
    1. Using a screwdriver, remove the O-ring from the direct clutch drum.
      Fig 95: Identifying O-Ring From Direct Clutch Drum
      G04976157Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  76. REMOVE OVERDRIVE DIRECT CLUTCH HUB SUB-ASSEMBLY 
    1. Remove the thrust bearing race, thrust bearing, and overdrive direct clutch hub from the planetary gear assembly.
      Fig 96: Identifying Overdrive Direct Clutch Hub Sub-Assembly
      G06011708Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  77. REMOVE REAR PLANETARY SUN GEAR ASSEMBLY 
    1. Remove the rear planetary sun gear assembly from the transaxle case.
      Fig 97: Identifying Rear Planetary Sun Gear Assembly
      G06011709Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the thrust needle roller bearing and thrust bearing race from the rear planetary sun gear assembly.
      Fig 98: Identifying Thrust Needle Roller Bearing And Thrust Bearing Race
      G04976160Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Remove the No. 2 planetary carrier thrust washer from the rear planetary sun gear assembly.
      Fig 99: Identifying No 2 Planetary Carrier Thrust Washer From Rear Planetary Sun Gear Assembly
      G06011711Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  78. REMOVE ONE-WAY CLUTCH ASSEMBLY 
    1. Remove the one-way clutch assembly and the thrust needle roller bearing from the transaxle case.
      Fig 100: Identifying One-Way Clutch Assembly
      G06011712Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the one-way clutch inner race from the one-way clutch assembly.
      Fig 101: Identifying One-Way Clutch Inner Race
      G06011713Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  79. REMOVE ONE-WAY CLUTCH SLEEVE 
    1. Remove the one-way clutch sleeve from the transaxle case.
      Fig 102: Identifying One-Way Clutch Sleeve
      G06011714Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  80. REMOVE NO. 1 PLANETARY CARRIER THRUST WASHER 
    1. Remove the No. 1 planetary carrier thrust washer from the planetary gear assembly.
      Fig 103: Identifying No 1 Planetary Carrier Thrust Washer
      G06011715Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  81. REMOVE 2ND BRAKE DISC 
    1. Using a screwdriver, remove the snap ring.
    2. Remove the flange, 3 discs and 3 plates from the transaxle case.
  82. INSPECT 2ND BRAKE DISC  (See INSPECTION )
    Fig 104: Identifying Snap Ring
    G04976166Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  83. REMOVE 2ND BRAKE PISTON ASSEMBLY 
    1. Using a screwdriver, remove the snap ring.
      Fig 105: Removing Snap Ring
      G04976257Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the 2nd brake piston assembly from the transaxle case.
      Fig 106: Identifying 2Nd Brake Piston Assembly
      G06011718Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  84. REMOVE 2ND BRAKE PISTON RETURN SPRING SUB-ASSEMBLY 
    1. Place SST on the return spring and compress it with a press.

      SST 09387-00060 

    2. Using a screwdriver, remove the snap ring.
      Fig 107: Removing Snap Ring
      G04976169Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Remove the 2nd brake piston return spring sub-assembly.
  85. INSPECT 2ND BRAKE PISTON RETURN SPRING SUB-ASSEMBLY  (See INSPECTION )
    Fig 108: Identifying 2Nd Brake Piston Return Spring Sub-Assembly
    G06011720Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  86. REMOVE 2ND BRAKE PISTON 
    1. Hold the 2nd brake piston and apply compressed air (392 kPa, 4.0 kgf/cm2 , 57 psi) to the 2nd brake cylinder to remove the 2nd brake piston.
      Fig 109: Applying Compressed Air To 2nd Brake Cylinder
      G05000982Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  87. REMOVE 2ND BRAKE PISTON O-RING 
    1. Remove the 2 O-rings from the 2nd brake piston.
      Fig 110: Identifying O-Rings From 2nd Brake Piston
      G04976172Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  88. REMOVE REAR PLANETARY GEAR ASSEMBLY 
    1. Using a screwdriver, remove the snap ring.
      Fig 111: Identifying Snap Ring
      G04976173Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the rear planetary gear assembly from the transaxle case.
      Fig 112: Identifying Rear Planetary Gear Assembly From Transaxle Case
      G06011724Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  89. REMOVE INPUT SUN GEAR 
    1. Remove the 2 thrust needle roller bearings, No. 2 thrust bearing races, No. 3 thrust bearing race, and input sun gear from the transaxle case.
      Fig 113: Identifying Input Sun Gear
      G06011725Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  90. REMOVE 1ST AND REVERSE BRAKE DISC 
    1. Remove the flange, 5 discs and 5 plates from the transaxle case.
  91. INSPECT 1ST AND REVERSE BRAKE DISC  (See INSPECTION )
    Fig 114: Identifying Discs And Plates From Transaxle Case
    G04976176Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  92. REMOVE FRONT PLANETARY GEAR ASSEMBLY 
    1. Using a chisel and hammer, unstake the lock washer.
      NOTE: Push down all claws of the washer. If the claws are not pushed down, SST cannot be fully pressed against the nut, and the nut cannot be loosened.
      Fig 115: Removing Front Planetary Gear Assembly
      G04976177Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using SST, remove the nut and washer.

      SST 09387-00030,09387-00080 

      Fig 116: Removing Nut And Washer
      G04976178Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Using SST and a press, remove the front planetary gear assembly from the counter drive gear.

      SST 09950-60010 (09951 -00450), 09950-70010 (09951-07100) 

      Fig 117: Removing Front Planetary Gear Assembly From Counter Drive Gear
      G04976179Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Remove the front planetary gear assembly from the brake hub.
      Fig 118: Removing Front Planetary Gear Assembly From Brake Hub
      G04976243Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  93. REMOVE FRONT PLANETARY RING GEAR 
    1. Using a screwdriver, remove the snap ring and front planetary ring gear from the brake hub.
      Fig 119: Identifying Front Planetary Ring Gear
      G06011731Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  94. REMOVE 1ST AND REVERSE BRAKE RETURN SPRING SUB-ASSEMBLY 
    1. Place SST on the return spring, and compress the return spring with a press.

      SST 09387-00070 

    2. Using a snap ring expander, remove the snap ring.
      NOTE:
      • Stop the press when the spring seat is lowered 1 to 2 mm (0.0393 to 0.0787 in.) from the snap ring groove to prevent the spring seat from being deformed.
      • Do not expand the snap ring excessively.
      Fig 120: Removing Snap Ring
      G04976182Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Remove the return spring.
  95. INSPECT 1ST AND REVERSE BRAKE RETURN SPRING SUB-ASSEMBLY  (See INSPECTION )
  96. REMOVE 1ST AND REVERSE BRAKE PISTON 
    1. Apply compressed air (392 kPa, 4.0 kgf/cm2 , 57 psi) to the transaxle case to remove the 1st and reverse brake piston.
      NOTE:
      • Applying compressed air may cause the piston to jump out. When removing the piston, hold it by hand using a piece of cloth.
      • Take care not to splash ATF when applying compressed air.
      Fig 121: Identifying 1st And Reverse Brake Piston
      G06011733Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the 2 O-rings from the 1st and reverse brake piston.
      Fig 122: Identifying O-Rings From 1st And Reverse Brake Piston
      G06011734Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  97. REMOVE COUNTER DRIVE GEAR BEARING 
    1. Using SST and a press, remove the counter drive gear from the transaxle case.

      SST 09950-60010 (09951 -00590), 09950-70010 (09951-07100) 

      Fig 123: Removing Counter Drive Gear Bearing
      G05559356Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Tighten the 2 bolts evenly and make a clearance of approximately. 20.0 mm (0.797 in.) between the counter drive gear and the inner race.
      Fig 124: Tightening Bolts
      G04976186Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Using SST, remove the tapered roller bearing inner race.

      SST 09950-00020, 09950-00030, 09950-60010 (09951-00590) 

      Fig 125: Identifying Roller Bearing Inner Race
      G04976187Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  98. REMOVE COUNTER DRIVE ANGULAR BALL BEARING 
    1. Remove the bearing inner race (rear side) and angular ball (rear side).
      Fig 126: Removing Counter Drive Angular Ball Bearing
      G04976188Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using SST, remove the bearing outer race (rear side) from the transaxle case.

      SST 09308-00010 

      Fig 127: Removing Bearing Outer Race (Rear Side) From Transaxle Case
      G04976189Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Remove the angular ball (front side).
      Fig 128: Identifying Angular Ball (Front Side)
      G04976190Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Using SST and a press, remove the bearing outer race (front side) from the transaxle case.

      SST 09950-60020 (09951 -00810), 09950-70010 (09951-07200) 

      Fig 129: Removing Bearing Outer Race (Front Side) From Transaxle Case
      G04976191Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Using a screwdriver, remove the snap ring from the transaxle case.
      Fig 130: Removing Snap Ring From Transaxle Case
      G05559363Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  99. REMOVE UNDERDRIVE BRAKE RETURN SPRING SUB-ASSEMBLY 
    1. Place SST on the return spring, and compress the return spring with a press.

      SST 09387-00020 

    2. Using a snap ring expander, remove the snap ring.
      NOTE:
      • Stop the press when the spring seat is lowered 1 to 2 mm (0.0393 to 0.0787 in.) from the snap ring groove to prevent the spring seat from being deformed.
      • Do not expand the snap ring excessively.
      Fig 131: Removing Snap Ring
      G04976193Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Remove the return spring.
  100. INSPECT UNDERDRIVE BRAKE RETURN SPRING SUB-ASSEMBLY  (See INSPECTION )
  101. REMOVE UNDERDRIVE BRAKE PISTON 
    1. Apply compressed air (392 kPa, 4.0 kgf/cm2 , 57 psi) to the transaxle case to remove the underdrive brake piston.
      Fig 132: Identifying Underdrive Brake Piston
      G06011744Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the 2 O-rings from the underdrive brake piston.
      Fig 133: Identifying O-Rings From Underdrive Brake Piston
      G06011745Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  102. REMOVE NEEDLE ROLLER BEARING 
    1. Using SST, remove the needle roller bearing from the transaxle case.

      SST 09387-00041 (09387-01010,09387-01030, 09387-01040) 

      Fig 134: Removing Needle Roller Bearing
      G04976196Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  103. REMOVE UNDERDRIVE CLUTCH DRUM OIL SEAL RING 
    1. Remove the 2 oil seal rings from the transaxle case.
      Fig 135: Identifying Underdrive Clutch Drum Oil Seal Ring
      G06011747Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  104. REMOVE NO. 1 TRANSAXLE CASE PLUG 
    1. Remove the 2 No. 1 transaxle case plugs.
    2. Remove the O-ring from each No. 1 transaxle case plug.
      Fig 136: Identifying No 1 Transaxle Case Plugs
      G06011748Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  105. REMOVE UNDERDRIVE CYLINDRICAL ROLLER BEARING 
    1. Using SST, remove the underdrive cylindrical roller bearing from the transaxle case.

      SST 09820-00031,09950-40011 (09952-04010, 09954-04010, 09955-04061, 09957-04010), 09950-50013 (09951-05010, 09953-05020) 

      Fig 137: Removing Underdrive Cylindrical Roller Bearing
      G04976199Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  106. REMOVE UNDERDRIVE OUTPUT SHAFT OIL SEAL RING 
    1. Remove the oil seal ring from the transaxle housing.
      Fig 138: Identifying Underdrive Output Shaft Oil Seal Ring
      G06011750Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  107. REMOVE DIFFERENTIAL GEAR LUBE APPLY TUBE 
    1. Remove the bolt, transaxle apply tube clamp and differential gear lube apply tube from the transaxle housing.
      Fig 139: Identifying Differential Gear Lube Apply Tube
      G06011751Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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