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Automatic Transmission Unit: Disassembly

  1. REMOVE TRANSMISSION CONTROL SHAFT LEVER LH 
    Fig 1: Identifying Nut, Washer & Control Shaft Lever LH
    G05191363Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Remove the nut, washer and control shaft lever LH.
  2. REMOVE PARK/NEUTRAL POSITION SWITCH ASSEMBLY 
    1. Using a screwdriver, pry out the lock washer.
      2. Fig 2: Identifying Nut, Lock Washer & Bolt
      G04963492Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the nut, lock washer and bolt.
    3. Remove the park/neutral position switch.
  3. REMOVE OIL COOLER TUBE UNION 
    Fig 3: Identifying Oil Cooler Tube Unions
    G04963493Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Remove the 2 oil cooler tube unions.
    2. Remove the O-ring from the oil cooler tube union.
  4. REMOVE SPEED SENSOR 
    Fig 4: Identifying Speed Sensors & Bolts
    G04963494Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Remove the 2 bolts and 2 speed sensors.
    2. Remove the O-ring from each sensor.
  5. REMOVE AUTOMATIC TRANSAXLE BREATHER TUBE 
    1. Remove the 2 bolts.
      2. Fig 5: Identifying Breather Tube
      G04965229Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the breather tube.
    3. Remove the O-ring from each tube.
  6. REMOVE AUTOMATIC TRANSMISSION HOUSING 
    1. Remove the 10 bolts.
    2. Remove the transmission housing.
  7. REMOVE TRANSMISSION CASE ADAPTER SUB-ASSEMBLY 
    Fig 6: Identifying Transmission Case Adapter Assembly Bolts
    G04963496Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Remove the 8 bolts.
    2. Remove the transmission case adapter assembly.

      HINT:

      Use a brass bar and a hammer to remove the extension housing assembly.

      3. Fig 7: Identifying Transmission Case Adapter Sub-Assembly
      G05191368Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Remove the gasket from the transmission case adapter sub-assembly.
  8. REMOVE TRANSMISSION CASE ADAPTER OIL SEAL 
    Fig 8: Prying Out Oil Seal Using Screwdriver
    G05191369Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Using a screwdriver, pry out the oil seal.
  9. FIX AUTOMATIC TRANSMISSION CASE SUB-ASSEMBLY 
    Fig 9: Identifying Transmission Case On Overhaul Attachment
    G04963501Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Install the transmission case on the overhaul attachment.
  10. REMOVE AUTOMATIC TRANSMISSION OIL PAN SUB-ASSEMBLY 
    NOTE: Do not turn the transmission over as this will contaminate the valve body with foreign matter on the bottom of the pan.
    1. Remove the drain plug and 20 bolts.
  11. INSPECT AUTOMATIC TRANSMISSION OIL PAN SUB-ASSEMBLY (See  INSPECTION   ) 
  12. REMOVE VALVE BODY OIL STRAINER ASSEMBLY 
    Fig 10: Identifying Valve Body Oil Strainer Assembly Bolts
    G04963502Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Turn over the transmission.
    2. Remove the 4 bolts holding the valve body oil strainer assembly to the valve body.
    3. Remove the O-ring form the valve body oil strainer assembly.
  13. REMOVE TRANSMISSION WIRE 
    1. Remove the ATF temperature sensor.
      2. Fig 11: Identifying Bolt & Clamp
      G04963503Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the bolt and clamp.
    3. Disconnect the 7 connectors from the shift solenoid valves.
      4. Fig 12: Identifying Transmission Wire Bolt
      G04963504Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Remove the bolt from the case.
    5. Pull the transmission wire out of the transmission case.
    6. Remove the O-ring from the transmission wire.
  14. REMOVE TRANSMISSION VALVE BODY ASSEMBLY 
    Fig 13: Identifying Valve Body Assembly Bolts
    G04963505Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Remove the 19 bolts.
    2. Remove the valve body assembly.
  15. REMOVE TRANSAXLE CASE GASKET 
    Fig 14: Identifying Transaxle Case Gaskets
    G04963506Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Remove the 3 transaxle case gaskets.
  16. REMOVE BRAKE DRUM GASKET 
    Fig 15: Identifying Brake Drum Gaskets
    G05261438Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Remove the 3 brake drum gaskets.
  17. REMOVE CHECK BALL BODY 
    Fig 16: Identifying Check Ball Body & Spring
    G04963508Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Remove the check ball body and spring.
  18. REMOVE C-2 ACCUMULATOR PISTON 
    Fig 17: Applying Compressed Air To Oil Hole To Remove C-2 Accumulator Piston & Spring
    G04963509Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Applying compressed air to the oil hole, and remove the C2 accumulator piston and spring.
    2. Remove the 2 O-rings from the piston.
    NOTE: Be careful as the C-3 and B-3 accumulator piston may jump out.
  19. REMOVE B-3 ACCUMULATOR PISTON 
    Fig 18: Applying Compressed Air To Oil Hole To Remove B-3 Accumulator Piston & Spring
    G04963509Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Applying compressed air to the oil hole, and remove the B3 accumulator piston and spring.
    2. Remove the 2 O-rings from the piston.
    NOTE: Be careful as the C-3 accumulator piston may jump out.
  20. REMOVE C-3 ACCUMULATOR PISTON 
    Fig 19: Applying Compressed Air To Oil Hole To Remove C-3 Accumulator Piston & Springs
    G04963511Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Applying compressed air to the oil hole, and remove the C3 accumulator piston and 2 spring.
    2. Remove the 2 O-rings from the piston.
  21. REMOVE C-1 ACCUMULATOR VALVE 
    Fig 20: Identifying C-1 Accumulator Valve & Springs
    G04963512Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Remove the C-1 accumulator valve and 2 springs.
  22. REMOVE PARKING LOCK PAWL BRACKET 
    Fig 21: Identifying Parking Lock Pawl Bracket Bolts
    G04963513Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Remove the 3 bolts and parking lock pawl bracket.
  23. REMOVE PARKING LOCK ROD SUB-ASSEMBLY 
    Fig 22: Identifying Parking Lock Rod
    G04963514Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Disconnect the parking lock rod from the manual valve lever.
  24. REMOVE PARKING LOCK PAWL SHAFT 
    Fig 23: Identifying Parking Lock Pawl & Spring
    G04965086Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Pull out the parking lock pawl shaft from the front side, and then remove the lock pawl and spring.
    2. Remove the E-ring from the shaft.
  25. REMOVE MANUAL VALVE LEVER SUB-ASSEMBLY 
    Fig 24: Cutting Off Spacer Using Hammer & Screwdriver
    G04963516Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Using a hammer and screwdriver, cut off the spacer and remove it from the shaft.
      2. Fig 25: Tapping Out Spring Pin Using Pin Punch & Hammer
      G04963517Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using a pin punch and hammer, tap out the spring pin.

      HINT:

      Slowly drive out the spring pin so that it does not fall into the transmission case.

    3. Pull the manual valve lever shaft out through the case, and remove the manual valve lever.
  26. REMOVE MANUAL VALVE LEVER SHAFT OIL SEAL 
    Fig 26: Using Screwdriver To Remove Oil Seals
    G04963518Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Using a screwdriver, remove the 2 oil seals.
  27. REMOVE OIL PUMP ASSEMBLY 
    Fig 27: Identifying Oil Pump Bolts
    G04963519Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Remove the 10 bolts holding the oil pump from the transmission case.
      2. Fig 28: Using SST To Remove Oil Pump
      G04963520Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using SST, remove the oil pump.

      SST 09350-30020 (09350-07020) 

      3. Fig 29: Identifying No. 1 Thrust Bearing Race
      G04963521Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Remove the No. 1 thrust bearing race from the front oil pump.
  28. REMOVE CLUTCH DRUM AND INPUT SHAFT ASSEMBLY 
    1. Remove the clutch drum and input shaft drum assembly from the transmission case.
      Fig 30: Removing Clutch Drum & Input Shaft Drum Assembly
      G04963522Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      2. Fig 31: Identifying Clutch Drum Thrust Washer & Thrust Needle Roller Bearing
      G04963523Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the clutch drum thrust washer and thrust needle roller bearing.
  29. INSPECT NO. 2 ONE-WAY CLUTCH ASSEMBLY (See  INSPECTION   ) 
  30. REMOVE NO. 2 ONE-WAY CLUTCH ASSEMBLY 
    Fig 32: Identifying No. 2 One-Way Clutch Assembly & No. 2 Clutch Drum Thrust Washer
    G04963524Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Remove the No. 2 one-way clutch assembly and No. 2 clutch drum thrust washer from the clutch drum and input shaft assembly.
  31. REMOVE NO. 3 BRAKE SNAP RING 
    Fig 33: Using Screwdriver To Remove No. 3 Brake Snap Ring
    G04963525Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Using a screwdriver, remove the No. 3 brake snap ring from the case.
  32. REMOVE NO. 3 BRAKE DISC 
    Fig 34: Identifying Flange & Cushion Plate
    G04963526Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Remove the flange and cushion plate the 4 discs and the 4 plates from the case.
  33. INSPECT NO. 3 BRAKE DISC (See  INSPECTION   ) 
  34. REMOVE 2ND BRAKE PISTON HOLE SNAP RING 
    Fig 35: Using SST To Remove Snap Ring
    G04963527Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Using SST, remove the snap ring.

    SST 09350-30020 (09350-07060) 

  35. REMOVE ONE-WAY CLUTCH ASSEMBLY 
    Fig 36: Identifying One-Way Clutch Assembly & No. 1 Planetary Carrier Thrust Washer
    G04963528Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Remove the one-way clutch assembly and the No. 1 planetary carrier thrust washer from the case.
  36. REMOVE 2ND BRAKE CYLINDER 
    Fig 37: Identifying 2nd Brake Cylinder
    G04963529Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Remove the 2nd brake cylinder from the case.
  37. REMOVE 2ND BRAKE PISTON 
    Fig 38: Using SST & Press To Remove Snap Ring
    G04963530Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Using SST and a press, remove the snap ring.

      SST 09351-40010 

      2. Fig 39: Applying Compressed Air To 2nd Brake Cylinder
      G04963531Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. 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.
    3. Remove the 2 O-rings from the 2nd brake piston.
  38. INSPECT NO. 3 BRAKE PISTON RETURN SPRING SUB-ASSEMBLY (See  INSPECTION   ) 
    Fig 40: Identifying O-Rings & 2nd Brake Piston
    G04963532Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  39. REMOVE FRONT PLANETARY GEAR ASSEMBLY 
    Fig 41: Identifying Front Planetary Gear Assembly & One-Way Clutch Inner Race
    G04963533Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Remove the front planetary gear assembly and the one-way clutch inner race from the case.
      2. Fig 42: Identifying Thrust Needle Roller Bearing, No. 3 Thrust Bearing Race & No. 2 Planetary Carrier Thrust Washer
      G04963534Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the thrust needle roller bearing, the No. 3 thrust bearing race and the No. 2 planetary carrier thrust washer from the front planetary gear assembly.
  40. INSPECT FRONT PLANETARY GEAR ASSEMBLY (See  INSPECTION   ) 
  41. INSPECT ONE-WAY CLUTCH ASSEMBLY (See  INSPECTION   ) 
  42. REMOVE FRONT PLANETARY RING GEAR 
    Fig 43: Identifying Front Planetary Ring Gear & Bearing
    G04963535Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Remove the front planetary ring gear and bearing from the transmission case.
  43. REMOVE CENTER PLANETARY RING GEAR 
    Fig 44: Using Screwdriver To Remove Snap Ring
    G04963536Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Using a screwdriver, remove the snap ring.
      2. Fig 45: Identifying Center Planetary Ring Gear & Front Planetary Ring Gear Flange
      G04963537Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the center planetary ring gear and front planetary ring gear flange from the front planetary ring gear.
  44. REMOVE NO. 1 BRAKE DISC 
    Fig 46: Identifying Flange, Discs & Plates
    G04963538Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Remove the flange, 3 discs and 3 plates from the case.
  45. INSPECT NO. 1 BRAKE DISC (See  INSPECTION   ) 
  46. REMOVE BRAKE PISTON RETURN SPRING SNAP RING 
    Fig 47: Using Screwdriver To Remove Brake Piston Return Spring Snap Ring
    G04963539Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Using a screwdriver, remove the brake piston return spring snap ring from the case.
  47. REMOVE BRAKE PISTON RETURN SPRING SUB-ASSEMBLY 
    Fig 48: Identifying Brake Piston Return Spring & No. 1 Brake Piston
    G04963540Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Remove the brake piston return spring and No. 1 the brake piston with the No. 1 brake cylinder from the transmission case.
  48. INSPECT BRAKE PISTON RETURN SPRING SUB-ASSEMBLY (See  INSPECTION   ) 
  49. REMOVE NO. 1 BRAKE PISTON 
    Fig 49: Applying Compressed Air To Transmission Case
    G04963541Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Hold the No. 1 brake piston and apply compressed air (392 kPa, 4 kgf/cm2 , 57 psi) to the transmission case to remove the No. 1 brake piston.

      HINT:

      If the piston does not pop out with compressed air, lift the piston out with needle-nose pliers.

    2. Remove the 2 O-rings from the No. 1 brake piston.
  50. REMOVE NO. 2 BRAKE DISC 
    Fig 50: Using Screwdriver To Remove Snap Ring From Case
    G04963542Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Using a screwdriver, remove the snap ring from the case.
      2. Fig 51: Identifying Flange, Brake Piston Return Spring & Discs
      G04963543Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the flange, the brake piston return spring, the 3 discs and the 3 plates from the case.
  51. INSPECT NO. 2 BRAKE DISC (See  INSPECTION   ) 
  52. INSPECT NO. 2 BRAKE PISTON RETURN SPRING SUB-ASSEMBLY (See  INSPECTION   ) 
  53. REMOVE NO. 2 BRAKE PISTON 
    Fig 52: Applying Compressed Air To Transmission Case
    G04963544Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Hold the No. 2 brake piston and apply compressed air (392 kPa, 4 kgf/cm2 , 57 psi) to the transmission case to remove the No. 2 brake piston.

      HINT:

      If the piston does not pop out with compressed air, lift the piston out with needle-nose pliers.

    2. Remove the 2 O-rings from the No. 2 brake piston.
  54. REMOVE CENTER PLANETARY GEAR ASSEMBLY 
    Fig 53: Identifying Center Planetary Gear Assembly, Planetary Sun Gear & No. 4 Thrust Bearing Race
    G04963545Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Remove the center planetary gear assembly, the planetary sun gear and the No. 4 thrust bearing race from the case.
  55. INSPECT CENTER PLANETARY GEAR ASSEMBLY (See  INSPECTION   ) 
  56. REMOVE INTERMEDIATE SHAFT 
    Fig 54: Using Screwdriver To Remove Snap Ring
    G04963546Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Using a screwdriver, remove the snap ring from the case.
      2. Fig 55: Identifying Intermediate Shaft With No. 3 One Way Clutch Assembly
      G04963547Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the intermediate shaft with the No. 3 one way clutch assembly from the case.
  57. INSPECT NO. 3 ONE-WAY CLUTCH ASSEMBLY (See  INSPECTION   ) 
  58. REMOVE NO. 3 ONE-WAY CLUTCH ASSEMBLY 
    Fig 56: Identifying No. 3 One-Way Clutch Assembly & One-Way Clutch Inner Race
    G04963548Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Remove the No. 3 one-way clutch assembly and the one-way clutch inner race from the intermediate shaft.
  59. REMOVE REAR PLANETARY RING GEAR FLANGE SUB-ASSEMBLY 
    Fig 57: Identifying No. 8 Thrust Bearing Race, Thrust Needle Roller Bearing, No. 7 Thrust Bearing Race & Planetary Ring Gear Flange
    G04963549Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Remove the No. 8 thrust bearing race, thrust needle roller bearing, the No. 7 thrust bearing race and the planetary ring gear flange from the intermediate shaft.
  60. INSPECT REAR PLANETARY RING GEAR FLANGE SUB-ASSEMBLY (See  INSPECTION   ) 
  61. INSPECT INTERMEDIATE SHAFT (See  INSPECTION   ) 
  62. REMOVE BRAKE PLATE STOPPER SPRING 
      Fig 58: Identifying Brake Plate Stopper Spring
      G04963550Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Remove the brake plate stopper spring from the case.
  63. REMOVE NO. 4 BRAKE DISC 
    Fig 59: Identifying Plates, Discs & Flanges
    G04963551Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Remove the 7 plates, the 8 discs and the 2 flanges from the case.
  64. INSPECT NO. 4 BRAKE DISC (See  INSPECTION   ) 
  65. REMOVE REAR PLANETARY GEAR ASSEMBLY 
    Fig 60: Identifying Rear Planetary Gear Assembly
    G04963552Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Remove the rear planetary gear assembly from the case.
      2. Fig 61: Identifying No. 9 Thrust Bearing Race & Thrust Needle Roller Bearing
      G04963553Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the No. 9 thrust bearing race and the thrust needle roller bearing from the rear planetary gear assembly.
      3. Fig 62: Identifying Thrust Needle Roller Bearing
      G04963554Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Remove the thrust needle roller bearing from the case.
  66. INSPECT REAR PLANETARY GEAR ASSEMBLY (See  INSPECTION   ) 
  67. REMOVE 1ST AND REVERSE BRAKE RETURN SPRING SUB-ASSEMBLY 
    1. Place SST on the spring retainer and compress the brake return spring.

      SST 09350-30020 (09350-07050) 

      2. Fig 63: Using SST To Remove Snap Ring
      G04963555Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using SST, remove the snap ring and the brake return spring.

    SST 09350-30020 (09350-07070) 

  68. INSPECT 1ST AND REVERSE BRAKE RETURN SPRING SUB-ASSEMBLY (See  INSPECTION   ) 
  69. REMOVE 1ST AND REVERSE BRAKE PISTON 
      Fig 64: Applying Compressed Air To Transmission Case
      G04963556Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Hold the 1st and reverse brake piston and apply compressed air (392 kPa, 4 kgf/cm2 , 57 psi) to the transmission case to remove the 1st and reverse brake piston.

      HINT:

      If the piston does not pop out with compressed air, lift the piston out with needle-nose pliers.

    2. Remove the O-ring from 1st and reverse brake piston.
  70. REMOVE BRAKE REACTION SLEEVE 
    Fig 65: Using SST To Remove Reaction Sleeve
    G04963557Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Using SST, remove the reaction sleeve.

      SST 09350-30020 (09350-07080) 

    2. Remove the O-ring from the reaction sleeve.
  71. REMOVE NO. 4 BRAKE PISTON 
    Fig 66: Using SST To Remove No. 4 Brake Piston
    G04965129Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Using SST, remove the No. 4 brake piston.

      SST 09350-30020 (09350-07090) 

    2. Remove the 2 O-rings from the No. 4 piston.
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