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Transmission Disassembly

  1. Remove wire harness. Remove transmission shaft lever and park/neutral position switch. Remove cooler line side unions. Remove speed sensor from extension housing. Remove OD direct clutch speed sensor from left forward side of transmission case. See Fig 2.
  2. Remove transmission converter housing from transmission case. Shift manual valve lever to "P" position. Unstake output flange lock nut and remove. Remove transmission output flange. Remove extension housing. Remove sensor rotor and 2 washers. Remove snap ring and No. 2 one-way clutch with retainer. See Fig 3.
  3. Remove transmission oil pan. To prevent contamination of valve body, do not turn transmission over. Remove oil strainer. Remove transmission fluid temperature sensor from brackets. Disconnect solenoid wires from brackets. Remove solenoid wiring. Remove valve body bolts and valve body. Note bolt length and location for reassembly reference. See Figure. 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 4-Fig 6 .
  4. Remove parking lock pawl bracket. Disconnect parking lock 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 spring pin. Remove manual valve lever shaft through transmission case. Remove manual valve lever.
  5. 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 3. Remove overdrive planetary ring gear. Remove bearing and race.
  6. Check overdrive brake piston stroke. Install a dial indicator onto overdrive (OD) brake piston. Measure piston stroke by applying 57-114 psi (4-8 kg/cm2 ) compressed air to opening in case. See OD BRAKE PISTON STROKE SPECIFICATIONS  table. See Fig 7. If piston stroke is not within specification, inspect clutch discs.
    OD BRAKE PISTON STROKE SPECIFICATIONS

    Application In. (mm)
    V8 Models .055-.067 (1.40-1.70)
    6-Cyl. Models .052-.064 (1.32-1.62)
  7. Remove snap ring. Remove OD brake clutch pack flanges, plates and discs. Note number and location of all components. 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 overdrive support assembly.
  8. Place reference mark on 3rd 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 8 and Fig 9 . Piston stroke should be .079-.118" (2.00-3.00 mm). If stroke is not within specification, inspect brake band.
  9. Remove 3rd coast brake cover snap ring. Carefully apply air pressure to oil hole as in step  8 to remove cover, piston and spring. Remove direct clutch with forward clutch from case. Remove bearings and race from clutch assembly.
  10. Remove "E" ring from 3rd coast brake band pin and remove pin. Remove 3rd coast brake band. Remove forward clutch hub and sun gear input drum. Remove 2 brake drum gaskets from case. See Fig 10.
  11. Remove snap ring securing No. 1 one-way clutch. Remove No. 1 one-way clutch with thrust washer. Remove multiple disc brake from case. See Fig 3.
  12. Place transmission on end and support output shaft on wooden blocks. Remove snap ring located above front planetary gear. Remove front planetary gear. Remove front and center sun gear.
  13. Remove 2nd brake pack flange, plates and discs. Note number and location of all components. Remove spring (retainer) from case. Remove output shaft with center and rear planetary gear. From rear of case, remove rear planetary snap ring. Remove rear planetary ring gear with thrust bearing and races.
Fig 1: Locating Check Ball Body & Spring
G95A20370Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Fig 2: Exploded View Of Transmission Case External Components
G00182360Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Fig 3: Exploded View Of Transmission Case Internal Components
G99A03683Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Fig 4: Removing 3rd Brake & Direct Clutch Accumulator Piston & Spring
G93D25711Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Fig 5: Removing Overdrive Brake Accumulator Piston & Spring
G93E25712Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Fig 6: Removing Overdrive Direct Clutch Accumulator Piston & Spring
G93F25713Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Fig 7: Measuring Overdrive Brake Piston Stroke
G96H04898Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Fig 8: Identifying 3rd Coast Brake Piston Rod Reference Mark Location
G93J25717Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Fig 9: Checking 3rd Coast Brake Piston Stroke Clearance
G93A25718Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Fig 10: Locating Brake Drum Gaskets
G99I04808Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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