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Automatic Transmission Unit: Disassembly

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

      Fig 6: Locating Transmission Housing Bolts
      G04963496Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Remove the gasket from the transmission case adapter sub-assembly.
      Fig 7: Identifying Transmission Case Adapter Sub-Assembly
      G05191368Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  8. REMOVE TRANSMISSION CASE ADAPTER OIL SEAL 
    1. Using a screwdriver, pry out the oil seal.
      Fig 8: Prying Oil Seal
      G05191369Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  9. FIX AUTOMATIC TRANSMISSION CASE SUB-ASSEMBLY 
    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.
    Fig 9: Identifying Transmission Case On Overhaul Attachment
    G04963501Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    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 
    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.
      Fig 10: Locating Transmission Bolts
      G04963502Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  13. REMOVE TRANSMISSION WIRE 
    1. Remove the ATF temperature sensor
    2. Remove the bolt and clamp.
    3. Disconnect the 7 connectors from the shift solenoid valves.
      Fig 11: Identifying Transmission Wire Clamp
      G04963503Courtesy 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.
      Fig 12: Locating Transmission Wire Bolts
      G04963504Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  14. REMOVE TRANSMISSION VALVE BODY ASSEMBLY 
    1. Remove the 19 bolts.
    2. Remove the valve body assembly.
      Fig 13: Identifying Valve Body Assembly
      G04963505Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  15. REMOVE TRANSAXLE CASE GASKET 
    1. Remove the 3 transaxle case gaskets.
      Fig 14: Identifying Transaxle Case Gaskets
      G04963506Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  16. REMOVE BRAKE DRUM GASKET 
    1. Remove the 3 brake drum gaskets.
      Fig 15: Identifying Brake Drum Gaskets
      G04963507Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  17. REMOVE CHECK BALL BODY 
    1. Remove the check ball body and spring.
      Fig 16: Removing Check Ball Body And Spring
      G04963508Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  18. REMOVE C-2 ACCUMULATOR PISTON 
    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.
      Fig 17: Removing C-2 Accumulator Piston
      G04963509Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  19. REMOVE B-3 ACCUMULATOR PISTON 
    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.
      Fig 18: Removing C-2 Accumulator Piston
      G04963509Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  20. REMOVE C-3 ACCUMULATOR PISTON 
    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.
      Fig 19: Applying Compressed Air To Oil Hole
      G04963511Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  21. REMOVE C-1 ACCUMULATOR VALVE 
    1. Remove the C-1 accumulator valve and 2 springs.
      Fig 20: Identifying C-1 Accumulator Valve And Springs
      G04963512Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  22. REMOVE PARKING LOCK PAWL BRACKET 
    1. Remove the 3 bolts and parking lock pawl bracket.
      Fig 21: Removing Parking Lock Pawl Bracket
      G04963513Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  23. REMOVE PARKING LOCK ROD SUB-ASSEMBLY 
    1. Disconnect the parking lock rod from the manual valve lever.
      Fig 22: Removing Parking Lock Rod Sub-Assembly
      G04963514Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  24. REMOVE PARKING LOCK PAWL SHAFT 
    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.
      Fig 23: Identifying Parking Lock Pawl Shaft
      G04965086Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  25. REMOVE MANUAL VALVE LEVER SUB-ASSEMBLY 
    1. Using a hammer and screwdriver, cut off the spacer and remove it from the shaft.
      Fig 24: Removing Manual Valve Lever Sub-Assembly
      G04963516Courtesy 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.
      Fig 25: Tapping Spring Pin
      G04963517Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  26. REMOVE MANUAL VALVE LEVER SHAFT OIL SEAL 
    1. Using a screwdriver, remove the 2 oil seals.
      Fig 26: Removing Oil Seals
      G04963518Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  27. REMOVE OIL PUMP ASSEMBLY 
    1. Remove the 10 bolts holding the oil pump from the transmission case.
      Fig 27: Removing Oil Pump Bolts
      G04963519Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using SST, remove the oil pump.

      SST 09350-30020 (09350-07020) 

      Fig 28: Removing Oil Pump
      G04963520Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Remove the No. 1 thrust bearing race from the front oil pump.
      Fig 29: Identifying No. 1 Thrust Bearing Race Of Front Oil Pump
      G04963521Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  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 And Input Shaft Assembly
      G04963522Courtesy 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  )
    Fig 31: Identifying Clutch Drum Thrust Washer And Thrust Needle Roller Bearing
    G04963523Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  30. REMOVE NO. 2 ONE-WAY CLUTCH ASSEMBLY 
    1. Remove the No. 2 one-way clutch assembly and No. 2 clutch drum thrust washer from the clutch drum and input shaft assembly.
      Fig 32: Identifying No. 2 One-Way Clutch Assembly
      G04963524Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  31. REMOVE NO. 3 BRAKE SNAP RING 
    1. Using a screwdriver, remove the No. 3 brake snap ring from the case.
      Fig 33: Removing No. 3 Brake Snap Ring
      G04963525Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  32. REMOVE NO. 3 BRAKE DISC 
    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  )
    Fig 34: Identifying No. 3 Brake Disc
    G04963526Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  34. REMOVE 2ND BRAKE PISTON HOLE SNAP RING 
    1. Using SST, remove the snap ring.

      SST 09350-30020 (09350-07060) 

      Fig 35: Removing 2ND Brake Piston Hole Snap Ring
      G04963527Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  35. REMOVE ONE-WAY CLUTCH ASSEMBLY 
    1. Remove the one-way clutch assembly and the No. 1 planetary carrier thrust washer from the case
      Fig 36: Identifying One-Way Clutch Assembly
      G04963528Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  36. REMOVE 2ND BRAKE CYLINDER 
    1. Remove the 2nd brake cylinder from the case.
      Fig 37: Removing 2ND Brake Cylinder
      G04963529Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  37. REMOVE 2ND BRAKE PISTON 
    1. Using SST and a press, remove the snap ring.

      SST 09351-40010 

      Fig 38: Removing 2ND Brake Piston
      G04963530Courtesy 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.
      Fig 39: Applying Compressed Air To 2Nd Brake Cylinder
      G04963531Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    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 No. 3 Brake Piston Return Spring Sub-Assembly
    G04963532Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  39. REMOVE FRONT PLANETARY GEAR ASSEMBLY 
    1. Remove the front planetary gear assembly and the one-way clutch inner race from the case.
      Fig 41: Identifying Front Planetary Gear Assembly
      G04963533Courtesy 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  )
    Fig 42: Identifying Thrust Needle Roller Bearing, No. 3 Thrust Bearing Race And No. 2 Planetary Carrier Thrust Washer
    G04963534Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  42. REMOVE FRONT PLANETARY RING GEAR 
    1. Remove the front planetary ring gear and bearing from the transmission case
      Fig 43: Identifying Front Planetary Ring Gear
      G04963535Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  43. REMOVE CENTER PLANETARY RING GEAR 
    1. Using a screwdriver, remove the snap ring.
      Fig 44: Removing Snap Ring
      G04963536Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the center planetary ring gear and front planetary ring gear flange from the front planetary ring gear
      Fig 45: Identifying Center Planetary Ring Gear And Front Planetary Ring Gear Flange
      G04963537Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  44. REMOVE NO. 1 BRAKE DISC 
    1. Remove the flange, 3 discs and 3 plates from the case.
  45. INSPECT NO. 1 BRAKE DISC  (See INSPECTION  )
    Fig 46: Identifying No. 1 Brake Disc
    G04963538Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  46. REMOVE BRAKE PISTON RETURN SPRING SNAP RING 
    1. Using a screwdriver, remove the brake piston return spring snap ring from the case.
      Fig 47: Removing Brake Piston Return Spring Snap Ring
      G04963539Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  47. REMOVE BRAKE PISTON RETURN SPRING SUB-ASSEMBLY 
    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  )
    Fig 48: Identifying Brake Piston Return Spring And No. 1
    G04963540Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  49. REMOVE NO. 1 BRAKE PISTON 
    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.
      Fig 49: Applying Compressed Air To Transmission Case
      G04963541Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  50. REMOVE NO. 2 BRAKE DISC 
    1. Using a screwdriver, remove the snap ring from the case.
      Fig 50: Removing No. 2 Brake Disc
      G04963542Courtesy 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  )
    Fig 51: Identifying Discs And Plates
    G04963543Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  53. REMOVE NO. 2 BRAKE PISTON 
    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.
      Fig 52: Applying Compressed Air To Transmission Case
      G04963544Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  54. REMOVE CENTER PLANETARY GEAR ASSEMBLY 
    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  )
    Fig 53: Identifying Center Planetary Gear Assembly
    G04963545Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  56. REMOVE INTERMEDIATE SHAFT 
    1. Using a screwdriver, remove the snap ring from the case.
      Fig 54: Removing Snap Ring Of Case
      G04963546Courtesy 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  )
    Fig 55: Removing Intermediate Shaft With No. 3 One-Way Clutch Assembly
    G04963547Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  58. REMOVE NO. 3 ONE-WAY CLUTCH ASSEMBLY 
    1. Remove the No. 3 one-way clutch assembly and the one-way clutch inner race from the intermediate shaft.
      Fig 56: Identifying No. 3 One-Way Clutch Assembly
      G04963548Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  59. REMOVE REAR PLANETARY RING GEAR FLANGE SUB-ASSEMBLY 
    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  )
    Fig 57: Identifying Rear Planetary Ring Gear Flange Sub-Assembly
    G04963549Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  62. REMOVE BRAKE PLATE STOPPER SPRING 
    1. Remove the brake plate stopper spring from the case.
      Fig 58: Locating Brake Plate Stopper Spring Of Case
      G04963550Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  63. REMOVE NO. 4 BRAKE DISC 
    1. Remove the 7 plates, the 8 discs and the 2 flanges from the case.
  64. INSPECT NO. 4 BRAKE DISC  (See INSPECTION  )
    Fig 59: Identifying No. 4 Brake Disc
    G04963551Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  65. REMOVE REAR PLANETARY GEAR ASSEMBLY 
    1. Remove the rear planetary gear assembly from the case.
      Fig 60: Identifying Rear Planetary Gear Assembly Of Case
      G04963552Courtesy 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.
      Fig 61: Identifying Thrust Needle Roller Bearing And Race
      G04963553Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Remove the thrust needle roller bearing from the case
  66. INSPECT REAR PLANETARY GEAR ASSEMBLY  (See INSPECTION  )
    Fig 62: Identifying Thrust Needle Roller Bearing Of Case
    G04963554Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  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. 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  )
    Fig 63: Removing Snap Ring And Brake Return Spring
    G04963555Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  69. REMOVE 1ST AND REVERSE BRAKE PISTON 
    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.
      Fig 64: Identifying Compressed Air To Transmission Case
      G04963556Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  70. REMOVE BRAKE REACTION SLEEVE 
    1. Using SST, remove the reaction sleeve.

      SST 09350-30020 (09350-07080) 

    2. Remove the O-ring from the reaction sleeve.
      Fig 65: Removing Brake Reaction Sleeve
      G04963557Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  71. REMOVE NO. 4 BRAKE PISTON 
    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.
      Fig 66: Removing No. 4 Brake Piston
      G04965129Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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