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Transaxle Disassembly

  1. Remove transaxle drain plug and drain transaxle. See Fig 1. Remove nut, washer and control shaft lever. Using a screwdriver, unstake nut stopper. Remove lock nut and stopper. Remove 2 bolts and pull out park/neutral position switch. See Fig 2.
  2. Remove oil line union and elbow. Remove and discard "O" rings from union and elbow. Remove counter gear and turbine speed sensors from top of transaxle. Remove and discard speed sensor "O" rings. Remove transaxle case plugs from transaxle case. Remove and discard case plug "O" rings. See Fig 1.
  3. Place transaxle on wooden blocks. Remove 18 bolts, oil pan and gasket. Remove 3 magnets from oil pan. See Fig 2. Disconnect 7 shift solenoid valve connectors. Remove bolt, lock plate and ATF temperature sensor. See Fig 3. Remove bolt and transaxle wiring harness with solenoid connectors from transaxle case. Remove 3 bolts, oil strainer and gasket. Remove 17 bolts and valve body assembly. See Fig 4.
  4. Remove governor apply gasket No. 1 and 2nd brake gasket from transaxle case. See Fig 5. Remove brake drum gasket from transaxle case. See Fig 6. Remove check ball body and spring from transaxle case. See Fig 7. Remove spring from underdrive clutch accumulator piston. See Fig 8.
  5. Using 57 psi (4 kg/cm2 ) of compressed air applied to transaxle case, remove underdrive clutch accumulator piston. See Fig 9. Cover accumulator piston with shop towel during removal. Remove and discard "O" ring from piston.
    Fig 1: Locating Case Plugs & Speed Sensors
    G00182258Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    Fig 2: Exploded View Of Transaxle External Components
    G00182257Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    Fig 3: Disconnecting Solenoid Valves & Removing Temperature Sensor
    G00182259Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    Fig 4: Removing Valve Body Assembly Bolts
    G00182260Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    Fig 5: Removing Governor Apply Gasket No. 1 & 2nd Brake Gasket
    G00182261Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    Fig 6: Removing Brake Drum Gasket
    G00182262Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    Fig 7: Removing Check Ball Body & Spring
    G00182263Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    Fig 8: Removing Spring From Underdrive Clutch Accumulator Piston
    G00182264Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    Fig 9: Removing Underdrive Clutch Accumulator Piston
    G00011244Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  6. Using 57 psi (4 kg/cm2 ) of compressed air applied to transaxle case, remove reverse clutch accumulator piston and spring, and underdrive brake accumulator piston with 2 springs. Cover pistons with shop towel during removal. See Fig 10 and Fig 11 . Remove and discard "O" rings from pistons.
  7. Using needle nose pliers, remove manual valve lever retainer spring. Remove 2 bolts, manual detent spring and cover. See Fig 2. Remove 2 bolts and parking lock pawl bracket. Using a hammer and chisel, unstake and remove spacer. Using a pin punch and hammer, drive out slotted spring pin. Ensure pin does not fall into transaxle case.
  8. Remove manual valve lever shaft and manual valve lever. Remove parking lock rod from manual valve lever. Using a screwdriver, remove shaft oil seal from transaxle case. See Fig 2. Position transaxle case with oil pump assembly facing upward.
    CAUTION: Use caution when removing transaxle housing. Differential assembly may attach to transaxle housing during removal.
  9. Using a dial indicator, measure input shaft end play and record measurement. See Fig 12. End play should be .0103-.0492" (.262-1.249 mm). Remove 16 transaxle housing bolts. Note bolt length and location during removal for reassembly reference. See Fig 13.
    Fig 10: Removing Reverse Clutch Accumulator Piston
    G00011245Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    Fig 11: Removing Underdrive Brake Accumulator Piston
    G00011246Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    Fig 12: Measuring Input Shaft End Play
    G00011247Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    Fig 13: Locating Transaxle Housing Bolts
    G00182308Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  10. Remove 7 oil pump bolts and oil pump from transaxle case. Remove thrust needle roller bearing from underdrive planetary gear. Remove thrust bearing underdrive race No. 2 from underdrive planetary gear. Remove differential assembly. See Fig 15. Remove 2 overdrive brake gaskets from transaxle case. See Fig 16. Remove forward clutch from transaxle case. Remove thrust needle roller bearing from forward clutch. Remove thrust needle roller bearing, multiple disc clutch hub, thrust needle roller bearing and bearing race No. 1 from transaxle case. See Fig 14.
  11. Using a dial indicator, measure inside diameter of multiple disc clutch hub bushing. See Fig 17. Standard diameter should be .9065-.9073" (23.025-23.046 mm). Maximum diameter is .9091" (23.090 mm). If diameter exceeds maximum specification, replace multiple disc clutch hub. Check bushing contact surface in clutch hub shaft for scratches or discoloration. Replace as necessary.
  12. Remove one bolt and pawl shaft clamp. Remove parking lock pawl shaft. See Fig 15. Push parking lock pawl toward transaxle case to prevent interference during underdrive planetary gear removal. See Fig 18. Using both hands, remove underdrive planetary gear. DO NOT allow planetary gear to separate.
  13. Remove torsion spring, pawl pin and parking lock pawl. Remove underdrive clutch assembly, needle roller bearing and thrust bearing race from transaxle case. See Fig 15. Using a screwdriver, remove underdrive one-way clutch snap ring. Remove one-way clutch from transaxle case. Note position of index marks on one-way clutch for reassembly reference. See Figure. Note position of outer race retainer on one-way clutch for reassembly reference. See Fig 19. Remove outer race retainer from one-way clutch.
  14. Using a screwdriver, remove underdrive clutch snap ring. Remove flange, 4 discs and 4 plates from transaxle case. Note location of components during removal for reassembly reference. See Fig 15.
    Fig 14: Exploded View Of Transaxle Internal Components (1 Of 2)
    G00182266Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    Fig 15: Exploded View Of Transaxle Internal Components (2 Of 2)
    G00182267Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    Fig 16: Removing Overdrive Brake Gaskets
    G00182268Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    Fig 17: Measuring Hub Bushing Inside Diameter
    G00182269Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    Fig 18: Pushing Parking Lock Pawl Toward Case
    G00182270Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    Fig 19: Removing & Installing Outer Race Retainer
    G00011308Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  15. Remove 11 bolts and transaxle rear cover. If necessary, tap on circumference of rear cover with plastic hammer to remove cover. Remove 4 transaxle case plugs from transaxle rear cover. Remove "O" rings. See Fig 20. Remove 3 oil seal rings from transaxle rear cover. Using appropriate puller, remove needle roller bearing from transaxle rear cover, if necessary. See Fig 21. Using a screwdriver, remove 3 governor apply gaskets from rear of transaxle case. See Fig 15.
  16. Remove bolt, clamp and apply tube. Remove clutch apply tube. Remove brake apply tube from clamp. See Fig 15 and Fig 22 . Remove direct clutch with thrust bearing from transaxle case. Remove thrust bearing race, thrust bearing and overdrive direct clutch hub from planetary gear. See Fig 14.
  17. Using a dial indicator, measure inside diameter of overdrive direct clutch hub bushing. See Fig 17. Standard diameter should be .9065-.9073" (23.025-23.046 mm). Maximum diameter is .9091" (23.090 mm). If diameter exceeds maximum specification, replace overdrive direct clutch hub. Check bushing contact surface in clutch hub shaft for scratches or discoloration. Replace as necessary.
  18. Remove rear planetary sun gear from transaxle case. Remove thrust needle roller bearing and thrust bearing race from rear planetary sun gear. Remove thrust washer No. 2 from rear planetary sun gear. Remove one-way clutch and thrust bearing from transaxle case. Remove inner race from one-way clutch. See Fig 14.
  19. Remove one-way clutch outer sleeve from transaxle case. Note direction of component for reassembly reference. Remove planetary carrier thrust washer No. 1 from planetary gear. Using a screwdriver, remove 2nd brake snap ring. Remove flange, 4 discs and 4 plates from transaxle case. Note location of components during removal for reassembly reference. See Fig 14.
  20. Using a screwdriver, remove 2nd brake piston snap ring. Remove 2nd brake piston from transaxle case. Using a screwdriver, remove rear planetary gear snap ring. Remove rear planetary gear from transaxle case. Remove 2 thrust bearings, bearing race and input sun gear from transaxle case. See Fig 14.
  21. Remove 1st and reverse brake flange, 6 discs and 6 plates from transaxle case. Note location of components during removal for reassembly reference. Using a hammer and chisel, unstake washer located on counter drive gear. See Fig 14. Ensure all claws on washer are pushed down to allow socket to fit securely on nut. Using holding tool, socket and torque wrench with a fulcrum length of 6.30" (160.0 mm), remove nut. See Fig 23.
  22. Using appropriate adapter and press, remove front planetary gear from counter drive gear. See Fig 24. Remove front planetary gear from brake hub. See Fig 14. Using a screwdriver, remove snap ring and front planetary ring gear from brake hub.
    23. NOTE: In the following step, stop press when piston return spring seat is lowered .039-.079" (1.00-2.00 mm) from snap ring groove. This prevents spring seat from becoming deformed. DO NOT expand snap ring excessively.
  23. Using appropriate press, compress 1st and reverse brake piston return spring. Using snap ring expander, remove snap ring. Remove piston return spring. Using vernier calipers, measure spring free length together with spring seat. Standard length should be .611" (15.53 mm). Replace springs as needed.
  24. Using 57 psi (4 kg/cm2 ) of compressed air applied to transaxle case, remove 1st and reverse brake piston from case. See Fig 25. Cover piston with shop towel during removal. Remove "O" rings from piston.
  25. Using appropriate adapter and press, remove counter drive gear from transaxle case. Install and tighten 2 bolts opposite each other evenly on counter drive gear. Ensure clearance between counter drive gear and bearing race is about .787" (20.00 mm). Using bearing puller, remove rear tapered roller bearing from counter drive gear. See Fig 14. Using a snap ring expander, remove snap ring. Using appropriate adapter and press, remove bearing outer race.
    26. NOTE: In the following step, stop press when piston return spring seat is lowered .039-.079" (1.00-2.00 mm) from snap ring groove. This prevents spring seat from becoming deformed. DO NOT expand snap ring excessively.
  26. Using appropriate adapter and press, compress underdrive brake piston return spring. Using snap ring expander, remove snap ring. Remove press, adapter and return spring. See Fig 15. Using vernier calipers, measure spring free length together with spring seat. Standard length should be .553" (14.04 mm). Replace springs as needed.
  27. Using 57 psi (4 kg/cm2 ) of compressed air applied to transaxle case, remove underdrive brake piston from transaxle case. See Fig 26. Cover piston with shop towel during removal. Remove "O" rings from piston.
  28. Using appropriate puller, remove needle roller bearing from transaxle case. Remove 2 oil seal rings from transaxle case. See Fig 27. Remove 2 transaxle case No. 1 plugs. See Fig 28. Remove "O" rings from plugs. Using appropriate puller, remove cylindrical roller bearing from transaxle case.
  29. Remove oil seal ring from transaxle housing. See Fig 29. Remove bolt, clamp and differential gear lube apply tube from transaxle housing. See Fig 2.
    Fig 20: Removing Transaxle Rear Cover Plugs
    G00182271Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    Fig 21: Removing Needle Roller Bearing From Rear Cover
    G00182272Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    Fig 22: Removing Apply Tubes
    G00182273Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    Fig 23: Removing & Installing Counter Drive Gear Nut
    G00011252Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    Fig 24: Removing Front Planetary Gear From Counter Drive Gear
    G00011253Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    Fig 25: Removing 1st & Reverse Brake Piston
    G00182274Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    Fig 26: Removing Underdrive Brake Piston
    G00182275Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    Fig 27: Removing Underdrive Clutch Drum Oil Seal Rings
    G00182276Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    Fig 28: Removing Transaxle Case No. 1 Plugs
    G00182277Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    Fig 29: Removing & Installing Transaxle Housing Oil Seal Ring
    G00011309Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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