Transmission Disassembly

Remove wire harness. Remove transmission shaft lever and park/neutral position switch. Remove cooler line side unions. Remove No. 1 and No. 2 speed sensors from extension housing.
Remove transmission housing from transmission case. Remove extension housing. Remove speedometer drive gear snap ring, drive gear and lock ball from output shaft. Remove sensor rotor and key.
Remove transmission oil pan. To prevent contamination of valve body, DO NOT turn transmission over. Remove oil filter and solenoid wiring. Remove oil tubes (if equipped).
Remove valve body. Remove check ball body and spring. See Fig 1. Remove accumulator piston springs. Apply air pressure to proper passages of transmission case to remove accumulator pistons. See Fig 2-Fig 4 .

Fig 1: Locating Check Ball Body & Spring
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Remove parking lock pawl bracket. Disconnect parking rod from manual valve lever. Remove "E" ring from shaft. Carefully remove lock pawl, spring and shaft. Using chisel and hammer, cut and remove spacer from shaft. Drive out roll pin. Remove manual valve lever shaft through transmission case. Remove manual valve lever.
Remove oil pump from transmission case using appropriate puller. Remove overdrive planetary gear unit with overdrive direct clutch from case. Remove bearing and race. See Fig 5. Remove overdrive planetary ring gear. Remove bearing and race.
Check overdrive brake piston stroke. Install a dial indicator onto the overdrive (OD) brake piston. Measure piston stroke by applying 57-114 psi (4-8 kg/cm² ) compressed air to opening in case. Piston stroke should be .055-.067" (1.40-1.70 mm). See Fig 6. If piston stroke is not within specification, inspect clutch discs.
Remove snap ring. Remove OD brake clutch pack flanges, plates and discs. Note number and location of all components. Place reference mark on 2nd coast brake piston rod. Apply 57-114 psi (4.8 kg/cm² ) of air at opening of transmission case. Using wire gauge, measure clearance between reference mark and case. See Fig 7 and Fig 8 . Piston stroke should be .059-.118" (1.50-3.00 mm). If stroke is not within specification, inspect brake band.
Remove 2nd coast brake cover snap ring. Carefully apply air pressure to oil hole as in step 8 to remove cover, piston and spring. Remove thrust bearing and race from overdrive support assembly. Remove overdrive support-to-case bolts. Remove snap ring. Using appropriate puller, remove overdrive support assembly. Remove race from rear of support assembly. Remove direct clutch with forward clutch from case. Remove bearings and race from clutch assembly.
Remove "E" ring from 2nd coast brake band pin and remove pin. Remove 2nd coast brake band. Remove race from front planetary ring gear. Remove front planetary ring gear. Remove thrust bearing and race from inside ring gear. Remove race from front planetary gear. Place transmission on end, and support output shaft on wooden blocks. Remove snap ring located above front planetary gear. Remove front planetary gear. See Fig 5.
Remove sun gear drum and one-way clutch. Check clutch pack clearance of 2nd brake. See Fig 10. Clutch pack clearance should be .024-.078" (.61-1.98 mm). If clearance is not within specification, inspect condition of clutch discs. Remove flange snap ring. Remove flange, plates and discs. Note number and location of all components.
Check clutch pack clearance of 1st and reverse brake. See Fig 9. Clearance should be .024-.044" (.61-1.12 mm). If clearance is not within specification, inspect condition of clutch discs.
Remove 2nd brake piston sleeve. Remove rear planetary gear unit snap ring. Remove rear planetary gear, 2nd brake drum, 1st and reverse brake pack and output shaft as an assembly. Remove thrust bearing and race from case. Remove 2nd brake drum assembly. See Fig 5.
Remove 1st and reverse brake cushion plate, flange, plates and discs. Note number and location of all components. Remove leaf spring from case. Remove brake drum gasket from case.
Ensure 1st and reverse brake pistons move smoothly when applying compressed air into case. See Fig 11. Disassemble 1st and reverse brake piston. Install appropriate compressor on spring retainer, and compress return spring. See Fig 12. Remove snap ring. Remove piston return spring. Using compressed air, remove 1st and reverse brake piston No. 2. See Fig 11.
Insert Sleeve Remover (09350-07080) behind reaction sleeve. Remove reaction sleeve from case. See Fig 13 and Fig 14 . Insert Piston Remover (09350-07090) behind No. 1 brake piston. Remove No. 1 brake piston from case. Remove manual valve lever spacer from shaft. Remove pin. Pull shaft out through case, and remove lever. Remove 2 oil seals.