Automatic Transaxle Unit: Disassembly

1. Remove the bolt and speedometer driven hole cover sub-assembly from the transaxle housing.
   Fig 1: Locating Speedometer Driven Hole Cover Sub-Assembly And Bolt

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Remove the O-ring from the speedometer driven hole cover sub-assembly.

1. Remove the nut, washer, and control shaft lever.
   Fig 2: Locating Control Shaft Lever, Washer And Nut

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2. Using a screwdriver, unstake the lock plate and remove the manual valve shaft nut.
   Fig 3: Locating Manual Valve Shaft Nut And Lock Plate

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3. Remove the 2 bolts and pull out the park/neutral position switch assembly.
   Fig 4: Locating Park/Neutral Position Switch Assembly

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1. Remove the bolt and remove the speed sensor from the transaxle case.
   Fig 5: Locating Speed Sensor

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2. Remove the O-ring from the speed sensor.

1. Remove the 2 oil cooler tube unions from the transaxle case.
   Fig 6: Identifying Oil Cooler Tube Unions

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2. Remove the 2 O-rings from the 2 oil cooler tube unions.

1. Remove the 4 No. 1 transaxle case plugs from the transaxle housing and transaxle case.
   Fig 7: Locating No. 1 Transaxle Case Plugs And Transaxle Case

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2. Remove the No. 1 transaxle case plug from the transaxle case.
   Fig 8: Locating No. 1 Transaxle Case Plug

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3. Remove the 5 O-rings from the 5 No. 1 transaxle case plugs.

1. Remove the breather plug hose from the breather plug.

1. Remove the breather plug from the transaxle case.
   Fig 9: Identifying Breather Plug

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1. Secure the transaxle onto wooden blocks.

Fig 10: Identifying Transaxle Onto Wooden Blocks

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1. Remove the 19 bolts and remove the oil pan and oil pan gasket.
   Fig 11: Identifying Oil Pan Bolts

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2. Remove the 2 oil cleaner magnets from the oil pan.
   Fig 12: Identifying Oil Cleaner Magnets

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1. Remove the 3 bolts and remove the oil strainer assembly.
   Fig 13: Identifying Oil Strainer Assembly

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2. Remove the oil strainer gasket from the oil strainer assembly.
   Fig 14: Identifying Oil Strainer Gasket

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1. Disconnect the 5 solenoid connectors.
   Fig 15: Locating Solenoid Connectors

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2. Remove the bolt, lock plate and ATF temperature sensor.
3. Remove the 2 bolts and remove the detent spring cover and detent spring.
   Fig 16: Locating Manual Detent Spring And Cover

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4. Remove the 13 bolts and the valve body assembly from the transaxle case.
   Fig 17: Locating Valve Body Assembly And Bolts

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1. Remove the bolt and the transmission wire from the transaxle case.
   Fig 18: Locating Transaxle Case Bolt

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2. Remove the O-ring from the transmission wire.
   Fig 19: Locating Transmission Wire Location

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1. Remove the transaxle case 2nd brake gasket from the transaxle case.
   Fig 20: Locating Transaxle Case 2nd Brake Gasket

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1. Remove the transaxle case gasket from the transaxle case.
   Fig 21: Locating Transaxle Case Gasket

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1. Remove the brake drum gasket from the transaxle case.
   Fig 22: Identifying Brake Drum Gasket

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1. Remove the check ball body and spring from the transaxle case.

Fig 23: Identifying Check Ball Body

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1. Apply compressed air (392 kPa, 4.0 kgf/cm² , 57 psi) to the oil hole and remove the B-2 accumulator piston and spring.
   NOTE:

   • Applying compressed air may cause the piston to jump out. When removing the piston, hold it by hand using a piece of cloth.
   • Do not splash ATF when applying compressed air.
     Fig 24: Locating B-2 Accumulator Piston

     Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Remove the 2 O-rings from the B-2 accumulator piston.
   Fig 25: Locating O-rings And B-2 Accumulator Piston

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1. Apply compressed air (392 kPa, 4.0 kgf/cm² , 57 psi) to the oil hole and remove the C-3 accumulator piston and spring.
   NOTE:

   • Applying compressed air may cause the piston to jump out. When removing the piston, hold it by hand using a piece of cloth.
   • Do not splash ATF when applying compressed air.
   Fig 26: Locating C-3 Accumulator Piston

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2. Remove the 2 O-rings from the C-3 accumulator piston.
   Fig 27: Locating C-3 Accumulator Piston

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1. Apply compressed air (392 kPa, 4.0 kgf/cm² , 57 psi) to the oil hole and remove the C-2 accumulator piston and the spring.
   NOTE:

   • Applying compressed air may cause the piston to jump out. When removing the piston, hold it by hand using a piece of cloth.
   • Do not splash ATF when applying compressed air.
     Fig 28: Locating C-2 Accumulator Piston And Spring

     Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Remove the 2 O-rings from the C-2 accumulator piston.
   Fig 29: Locating C-2 Accumulator Piston

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1. Remove the 14 bolts.
2. Tap around the circumference of the transaxle housing with a plastic hammer to remove the transaxle housing from the transaxle case.

Fig 30: Locating Transaxle Housing Bolts

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1. Remove the 7 bolts and the oil pump assembly from the transaxle case.
   Fig 31: Locating Oil Pump Bolts

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1. Remove the differential gear assembly from the transaxle case.

Fig 32: Identifying Differential Gear Assembly

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1. Using a screwdriver, remove the 2 overdrive brake gaskets from the transaxle case.

Fig 33: Locating Overdrive Brake Gasket

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1. Remove the input shaft assembly from the transaxle case.
   Fig 34: Identifying Input Shaft Assembly

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1. Remove the stator shaft thrust needle roller bearing from the input shaft.
   Fig 35: Identifying Stator Shaft Thrust Needle Roller Bearing

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1. Using a screwdriver, remove the snap ring.
   Fig 36: Removing Front Clutch Disc

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2. Remove the flange, 4 discs and 4 plates from the input shaft.

1. Using SST on the clutch balancer, compress the return spring with a press.

   SST 09320-89010 

   NOTE: Do not compress the return spring excessively.
   Fig 37: Removing Forward Clutch Return Spring Sub-Assembly

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2. Using a snap ring expander, remove the snap ring.
3. Remove the clutch balancer and piston return spring.
   Fig 38: Identifying Clutch Balancer And Piston Return Spring

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Place the input shaft onto the oil pump.
2. Holding the forward clutch piston by hand, apply compressed air (392 kPa, 4.0 kgf/cm² , 57 psi) to the oil pump to remove the forward clutch piston.

HINT:

If the piston cannot be removed because it is tilted, either apply compressed air again while keeping the piston level or remove the piston using needle-nose pliers with its tips wrapped in protective tape.

Fig 39: Applying Compressed Air To Oil Pump

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1. Using a screwdriver, remove the clutch piston CD-ring from the forward clutch piston.
   Fig 40: Locating Forward Clutch Piston O-Ring

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1. Using a screwdriver, remove the input shaft oil seal ring from the input shaft.
   Fig 41: Identifying Input Shaft Oil Seal Ring

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1. Remove the forward clutch hub thrust needle roller bearing from the forward clutch hub.
   Fig 42: Identifying Forward Clutch Hub Thrust Needle Roller Bearing

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Remove the forward clutch hub sub-assembly from the transaxle case.
   Fig 43: Identifying Forward Clutch Hub Sub-Assembly

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1. Remove the 11 bolts.
2. Tap around the circumference of the rear transaxle cover with a plastic hammer to remove the rear transaxle cover from the transaxle case.

Fig 44: Locating Rear Transaxle Cover Bolts

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1. Remove the 4 rear transaxle cover plugs from the rear transaxle cover.
   Fig 45: Identifying Rear Transaxle Cover Plug

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2. Using a screwdriver, remove the 4 O-rings from the 4 rear transaxle cover plugs.

1. Using SST, a press and a screwdriver, remove the snap ring.

   SST 09387-00070 

   NOTE:

   • Stop the press when the spring seat is lowered 1 to 2 mm (0.0393 to 0.0787 in.) from the snap ring groove. This prevents the spring seat from being deformed.
   • Do not expand the snap ring excessively.
2. Remove the overdrive brake return spring sub-assembly from the rear transaxle cover.
   Fig 46: Identifying Overdrive Brake Return Spring Sub-Assembly

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Apply compressed air (392 kPa, 4.0 kgf/cm² , 57 psi) to the rear transaxle cover to remove the overdrive brake piston.

1. Using a screwdriver, remove the 2 O-rings from the 2nd coast and overdrive brake piston.
   Fig 48: Locating 2nd Coast And Overdrive O-Rings

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Remove the 3 oil seal rings from the rear transaxle cover.
   Fig 49: Locating Oil Seal Rings

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Using SST, remove the bearing from the rear transaxle cover.

   SST 09387-00041 (09387-01021) 

   Fig 50: Removing Rear Transaxle Cover Needle Roller Bearing

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Remove the 4 transaxle case gaskets.
   Fig 51: Identifying Transaxle Case Gaskets

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Using a magnetic pick-up tool, remove the rear clutch drum thrust needle roller bearing.
   Fig 52: Identifying Rear Clutch Drum Thrust Needle Roller Bearing

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Remove the intermediate shaft assembly from the transaxle case.
   Fig 53: Identifying Intermediate Shaft Assembly

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Using a screwdriver, remove the snap ring.
2. Remove the flange, 3 discs and 3 plates.
   Fig 54: Removing Reverse Clutch Discs

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Using a screwdriver, remove the snap ring.
2. Remove the direct clutch flange, 3 plates and 3 discs.
   Fig 55: Removing Direct Clutch Discs

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Using SST and a press.

   SST 09387-00020 

2. Using snap ring pliers, remove the snap ring.
3. Remove the direct clutch return spring sub-assembly from the intermediate shaft.
   Fig 56: Removing Direct Clutch Return Spring Sub-Assembly

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Install the intermediate shaft onto the rear transaxle cover.
2. Apply compressed air (392 kPa, 4.0 kgf/cm² , 57 psi) to the oil hole shown in the illustration and remove the direct clutch piston from the intermediate shaft.

1. Install the intermediate shaft onto the rear transaxle cover.
2. Put a matchmark on the direct clutch drum in the same position as the cutout of the intermediate shaft assembly.
3. Apply compressed air (392 kPa, 4.0 kgf/cm² , 57 psi) to the oil hole shown in the illustration and remove the direct clutch drum sub-assembly from the intermediate shaft.
   Fig 58: Applying Compressed Air To Oil Hole

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Using a screwdriver, remove the 2 piston O-rings from the direct clutch piston.
   Fig 59: Locating Direct Clutch Piston O-Ring

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Using a screwdriver, remove the direct clutch drum O-ring from the direct clutch drum.
   Fig 60: Locating Direct Clutch Drum O-Ring

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Remove the flange, 2 discs and 2 No. 2 plates from the transaxle.
   Fig 61: Identifying 2nd Coast And Overdrive Brake Disc

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Using a magnetic pick-up tool, remove the C-2 hub thrust bearing race, the thrust needle roller bearing and the No. 3 thrust bearing race from the direct clutch hub.
   Fig 62: Identifying Thrust Needle Roller Bearing

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Remove the direct clutch hub from the transaxle case.

Fig 63: Identifying Direct Clutch Hub And Transaxle Case

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1. Using a magnetic pick-up tool, remove the rear No. 2 planetary sun gear thrust needle roller bearing from the rear planetary sun gear assembly.
   Fig 64: Identifying Rear No. 2 Planetary Sun Gear Thrust Needle Roller Bearing

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Remove the rear planetary sun gear assembly from the transaxle case.
   Fig 65: Identifying Rear Planetary Sun Gear Assembly

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1. Remove the rear planetary sun gear thrust needle roller bearing and No. 1 planetary carrier thrust washer from the one-way clutch assembly.
   Fig 66: Identifying Rear Planetary Sun Gear Thrust Needle Roller Bearing

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Remove the one-way clutch assembly and No. 2 planetary carrier thrust washer from the rear planetary sun gear.
   Fig 67: Identifying One-Way Clutch Assembly

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1. Using a screwdriver, remove the 2 snap rings.
   Fig 68: Locating Snap Rings

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2. Remove the 2 flanges, 4 discs and 3 plates from the transaxle.

1. Remove the 2nd brake piston sleeve from the transaxle case.
   Fig 69: Identifying 2nd Brake Piston Sleeve

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Using a screwdriver, remove the snap ring.
   Fig 70: Identifying Rear Planetary Gear Assembly

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Remove the rear planetary gear assembly from the transaxle case.

1. Remove the thrust needle roller bearing and 2 bearing races from the rear planetary gear assembly.
   Fig 71: Identifying Rear Planetary Gear Thrust Needle Roller Bearing

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Separate the 2nd brake assembly, No. 2 one-way clutch and the rear planetary gear.
   Fig 72: Identifying No. 2 One-Way Clutch

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1. Remove the retainer from the No. 2 one-way clutch.
   Fig 73: Locating Outer Race Retainer

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1. Using SST and a press, remove the snap ring from the 2nd brake piston.

   SST 09387-00060 

   Fig 74: Removing 2nd Brake Piston Return Spring Sub-Assembly

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Remove the 2nd brake piston return spring sub-assembly from the 2nd brake cylinder.

1. 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 76: Applying Compressed Air To 2nd Brake Cylinder

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Using a screwdriver, remove the 2 O-rings from the 2nd brake cylinder.
   Fig 77: Identifying 2nd Brake Cylinder O-Ring

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Remove the front planetary sun gear and thrust needle roller bearing from the transaxle case.

Fig 78: Identifying Front Planetary Sun Gear

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1. Using a screwdriver, remove the snap ring.
   Fig 79: Identifying 1st And Reverse Brake Disc

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Remove the flange, 4 discs and 4 plates from the transaxle case.

1. Using SST, a press and a screwdriver, remove the snap ring.

   SST 09387-00070 

2. Remove the 1st and reverse brake return spring sub-assembly.
   Fig 80: Inspecting 1st And Reverse Brake Return Spring Sub-Assembly

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Apply compressed air (392 kPa, 4.0 kgf/cm² , 57 psi) to the transaxle case to remove the No. 2 1st and reverse brake piston.

1. Remove the 2 O-rings from the No. 2 1st and reverse brake piston.
   Fig 82: Identifying NO. 2 1st And Reverse Brake Piston O-Ring

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1. Secure the counter driven gear with the parking lock pawl.
   Fig 83: Identifying Counter Drive Gear Nut

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using SST and a hammer, release the lock nut washer.

   SST 09930-00010 

   Fig 84: Releasing Lock Nut Washer

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3. Using SST, remove the nut and lock nut washer.

   SST 09387-00120 

   Fig 85: Removing Nut And Lock Nut Washer

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1. Using SST and a press, remove the planetary gear assembly from the transaxle case.

   SST 09950-60010 (09951 -00320, 09951 -00400, 09952-06010), 09950-70010 (09951-07100) 

   Fig 86: Removing Planetary Gear Assembly

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Install 2 service bolts to the counter drive gear.

   Bolt (M6): 

   Length = 40 to 80 mm (1.57 to 3.15 in.) 

   Pitch = 1.0 mm (0.04 in.) 

2. Rotate the 2 bolts and remove the counter drive gear from the front planetary sun gear.
3. Remove the 2 radial ball bearings from the counter drive gear.
   Fig 87: Removing Counter Drive Gear

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Remove the 3 bolts, cam guide and pawl bracket from the transaxle case.
   Fig 88: Identifying Parking Lock Pawl Bracket

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Remove the manual valve lever shaft retainer spring from the manual valve lever shaft.
   Fig 89: Removing Manual Valve Lever Shaft Retainer Spring

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Using a screwdriver, release and remove the spacer.
   Fig 90: Removing Manual Valve Lever Sub-Assembly

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using a pin punch and hammer, drive out the manual valve lever shaft spring pin.
3. Remove the manual valve lever shaft and manual valve lever.

Fig 91: Removing Manual Valve Lever Shaft And Manual Valve Lever

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1. Remove the parking lock rod sub-assembly from the manual valve lever.

Fig 92: Identifying Parking Lock Rod Sub-Assembly

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Remove the manual valve lever shaft from the transaxle case.
   Fig 93: Identifying Manual Valve Lever Shaft

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Using a screwdriver, remove the parking lock pawl shaft from the transaxle case.
2. Remove the parking lock pawl torsion spring and parking lock pawl from the transaxle case.

Fig 94: Locating Parking Lock Pawl

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Remove the counter driven gear, drive pinion and thrust needle roller bearing from the transaxle case.
   Fig 95: Identifying Counter Driven Gear

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Using a brass bar and a hammer, remove the differential drive pinion plug.
   Fig 96: Removing Differential Drive Pinion Plug

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1. Using SST and a press, remove the differential drive pinion from the counter driven gear.

   SST 09950-60010 (09951 -00350), 09950-70010 (09951-07150) 

   Fig 97: Removing Differential Drive Pinion

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Remove the bolt and the bearing lock plate.

Fig 98: Locating Bearing Lock Plate And Bolt

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1. Remove the differential gear lube apply tube from the transaxle housing.

Fig 99: Locating Differential Gear Lube Apply Tube

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1. Using SST, remove the front drive pinion front tapered roller bearing from the transaxle housing.

   SST 09308-10010 

   Fig 100: Removing Front Drive Pinion Front Tapered Roller Bearing

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Using SST, remove the front drive pinion rear tapered roller bearing from the transaxle case.

   SST 09612-65014 (09612-01040) 

2. Remove the No. 1 transaxle case plate from the transaxle case.

1. Remove the counter drive gear bearing inner race LH and angular ball from the transaxle case.
   Fig 101: Removing Counter Drive Gear Bearing

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using SST, remove the counter drive gear bearing outer race LH from the transaxle case.

   SST 09308-00010 

1. Remove the counter drive gear bearing RH from the transaxle case.
   Fig 102: Removing Counter Drive Gear Bearing

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using SST, remove the counter drive gear bearing outer race RH from the transaxle case.

   SST 09308-00010 

   Fig 103: Removing Counter Drive Gear Bearing Outer Race

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Using a screwdriver, remove the counter drive gear hole snap ring from the transaxle case.
   Fig 104: Identifying Counter Drive Gear Hole Snap Ring

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Using a screwdriver, remove the manual valve lever shaft oil seal from the transaxle case.

Fig 105: Removing Manual Valve Lever Shaft Oil Seal

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Using SST and a hammer, remove the No. 2 transaxle case oil seal from the transaxle case.

   SST 09950-60010 (09951 -00550), 09950-70010 (09951-07100) 

   Fig 106: Removing No. 2 Transaxle Case Oil Seal

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002