Transmission Disassembly

NOTE: Note locations of all thrust bearings, thrust races and thrust washers for reassembly reference. See Figure.

Remove wire harness and throttle cable clamp. Remove transmission shaft lever and park/neutral position switch. Remove cooler line side unions. Remove transmission fluid temperature sensor from right side of transmission case. On V8 models, remove OD direct clutch speed sensor.
Remove breather hose from transfer upper cover and transmission shifter control retainer. Remove engine rear mounting. Remove dynamic damper (vibration damper) from transfer case. Remove drive shaft upper dust cover. Unbolt and remove transfer case from transmission. DO NOT damage adapter rear oil seal with transfer input gear spline.
Remove speed sensor snap ring, sensor rotor and key. Remove transmission housing from transmission case. Remove transfer case from transmission. Remove transmission oil pan. To prevent contamination of valve body, DO NOT turn transmission over.
Remove oil filter and solenoid wiring. Remove oil tube(s). Disconnect throttle cable from cam (if applicable). 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 . Remove throttle cable from transmission case.

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 6. Remove overdrive planetary ring gear. Remove bearing and race.

Check overdrive brake piston stroke. Install dial indicator on overdrive (OD) brake piston. Measure stroke by applying 57-114 psi (4-8 kg/cm² ) compressed air to opening in case. See Fig 7. See OD BRAKE PISTON STROKE SPECIFICATIONS table. If piston stroke is not within specifications, inspect clutch discs.

OD BRAKE PISTON STROKE SPECIFICATIONS

Application	Piston Stroke - In. (mm)
Lexus LX 470	.069-.081 (1.75-2.05)
Toyota Land Cruiser	.069-.081 (1.75-2.05)

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 8 and Fig 9 . 2nd coast brake 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 6.
Remove sun gear drum and one-way clutch. Check clutch pack clearance of second brake. See Fig 11. Clearance should be .024-.078" (.61-1.98 mm). If clearance is not within specifications, inspect condition of clutch discs. Remove flange snap ring.
Remove the flange, plates and discs. Note the number and location of all components. Check clutch pack clearance of 1st and reverse brake. See Fig 10. Clearance should be .028-.048" (.71-1.22 mm). If clearance is not within specifications, 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 6.
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 12. Disassemble 1st and reverse brake piston. Install appropriate compressor on spring retainer and compress return spring. See Fig 13. Remove snap ring. Remove piston return spring. Using compressed air, remove 1st and reverse brake piston No. 2. See Fig 12.
Insert Sleeve Remover (09350-07080) behind reaction sleeve. Remove reaction sleeve from case. See Fig 14 and Fig 15 . Insert Piston Remover (09350-07090) behind No. 1 brake piston. Remove No. 1 brake piston from case.