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Automatic Transaxle Unit: Disassembly: Disassembly

WARNING: This page is about a different variant/trim than selected.
  1. REMOVE PARK/NEUTRAL POSITION SWITCH ASSEMBLY 
    1. Remove the nut, washer and control shaft lever.
      Fig 1: Remove/Install Control Shaft Lever
      GTY245625Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using a screwdriver, unstake the lock plate.
      Fig 2: Prying Off Lock Plate
      GTY245623Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Remove the nut and lock plate.
    4. Remove the 2 bolts and pull out the switch.
      Fig 3: Installing Park/Neutral Position Switch Assembly
      GTY245620Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  2. REMOVE BREATHER PLUG HOSE 
  3. REMOVE OIL COOLER OUTLET TUBE UNION 
    1. Remove the union.
      Fig 4: Remove/Install Breather Plug Hose
      GTY216619Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the O-ring from the union.
  4. REMOVE OIL COOLER INLET TUBE UNION 
    1. Remove the union.
      Fig 5: Identifying Oil Cooler Inlet Tube Union
      GTY236101Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the O-ring from the union.
  5. REMOVE SPEED SENSOR 
    1. Remove the 2 bolts and 2 speed sensors from the transaxle.
      Fig 6: Remove/Install Speed Sensors
      GTY212389Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the 2 O-rings from the sensors.
  6. REMOVE NO. 1 TRANSAXLE CASE PLUG 
    1. Remove the 4 plugs from the transaxle case.
      Fig 7: Identifying No. 1 Transaxle Case Plugs
      GTY158680Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the 4 O-rings from the 4 plugs.
  7. SECURE AUTOMATIC TRANSAXLE ASSEMBLY 
    1. Secure the transaxle assembly onto wooden blocks.
      Fig 8: Fixing Automatic Transaxle Assembly
      GTY245610Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  8. REMOVE AUTOMATIC TRANSAXLE OIL PAN SUB-ASSEMBLY 
    1. Remove the 18 bolts.
      Fig 9: Inspecting Automatic Transaxle Oil Pan Sub-Assembly
      GTY157767Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the oil pan and 3 magnets.
    3. Remove the gasket from the oil pan.
  9. INSPECT TRANSMISSION OIL CLEANER MAGNET  See step  1
  10. REMOVE VALVE BODY OIL STRAINER ASSEMBLY 
    1. Remove the 3 bolts and oil strainer.
      Fig 10: Removing Valve Body Oil Strainer Assembly
      GTY245613Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the O-ring from the oil strainer.
      Fig 11: Locating O-Ring
      GTY157769Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  11. REMOVE TRANSMISSION WIRE 
    1. Disconnect the 5 shift solenoid valve connectors.
      Fig 12: Disconnecting Transmission Wire
      GTY158670Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the bolt, lock plate and ATF temperature sensor.
    3. Remove the bolt and transmission wire.
      Fig 13: Removing Bolt And Transaxle Solenoid Wire From Transaxle
      GTY157885Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Remove the O-ring from the transmission wire.
      Fig 14: Removing O-Ring
      GTY225228Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  12. REMOVE TRANSMISSION VALVE BODY ASSEMBLY 
    1. Support the valve body and remove the 17 bolts and valve body.
      Fig 15: Locating Transmission Valve Body Bolts
      GTY229472Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  13. REMOVE NO. 1 GOVERNOR APPLY GASKET 
    1. Remove the governor apply gasket from the transaxle case.
      Fig 16: Remove/Install No. 1 Governor Apply Gasket
      GTY166716Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  14. REMOVE TRANSAXLE CASE 2ND BRAKE GASKET 
    1. Remove the 2nd brake gasket from the transaxle case.
      Fig 17: Locating Transaxle Case 2nd Brake Gasket
      GTY159183Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  15. REMOVE BRAKE DRUM GASKET 
    1. Remove the brake drum gasket from the transaxle case.
      Fig 18: Locating Brake Drum Gasket
      GTY166079Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  16. REMOVE CHECK BALL BODY 
    1. Remove the check ball body and spring from the transaxle.
      Fig 19: Identifying Check Ball Body And Spring
      GTY165783Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  17. REMOVE C-3 ACCUMULATOR PISTON 
    1. Remove the spring from the C-3 accumulator piston.
      Fig 20: Removing Spring From C-3 Accumulator Piston
      GTY165222Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Apply compressed air (392 kPa, 4.0 kgf/cm2 , 57 psi) to the oil hole and remove the C-3 accumulator piston.
      Fig 21: Apply Compressed Air To Oil Hole
      GTY157890Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      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 spatter ATF when applying compressed air.
    3. Remove the O-ring from the C-3 accumulator piston.
      Fig 22: Removing O-Ring From C-3 Accumulator Piston
      GTY163902Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  18. REMOVE C-1 ACCUMULATOR PISTON 
    1. Apply compressed air (392 kPa, 4.0 kgf/cm2 , 57 psi) to the oil hole and remove the C-1 accumulator piston and spring.
      Fig 23: Removing C-1 Accumulator Piston And Compression Spring
      GTY245538Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      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 spatter ATF when applying compressed air.
    2. Remove the 2 O-rings from the C-1 accumulator piston.
      Fig 24: Locating O-Rings
      GTY157831Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  19. REMOVE B-3 ACCUMULATOR PISTON 
    1. Apply compressed air (392 kPa, 4.0 kgf/cm2 , 57 psi) to the oil hole and remove the B-3 accumulator piston and 2 springs.
      Fig 25: Apply Compressed Air To Oil Hole
      GTY157891Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      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 spatter ATF when applying compressed air.
    2. Remove the O-ring from the B-3 accumulator piston.
      Fig 26: Removing O-Ring From B-3 Accumulator Piston
      GTY166522Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  20. REMOVE MANUAL DETENT SPRING SUB-ASSEMBLY 
    1. Remove the 2 bolts, manual detent spring and cover.
      Fig 27: Removing Bolts, Manual Detent Spring And Cover
      GTY157894Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  21. REMOVE PARKING LOCK PAWL BRACKET 
    1. Remove the 2 bolts and parking lock pawl bracket.
      Fig 28: Removing Bolts And Parking Lock Pawl Bracket
      GTY159466Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  22. REMOVE MANUAL VALVE LEVER SHAFT RETAINER SPRING 
    1. Using needle-nose pliers, remove the retainer spring.
      Fig 29: Removing Manual Valve Lever Shaft Retainer Spring
      GTY157892Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  23. REMOVE MANUAL VALVE LEVER SUB-ASSEMBLY 
    1. Using a chisel and hammer, unstake and remove the spacer.
      Fig 30: Removing Spacer
      GTY243466Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using a pin punch and hammer, tap out the pin.
      Fig 31: Driving Out Pin
      GTY157895Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      HINT: 

      Slowly tap out the pin so that it will not fall into the transaxle.

    3. Remove the manual valve lever shaft and manual valve lever.
      Fig 32: Removing Manual Valve Lever Shaft And Manual Valve Lever
      GTY157896Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  24. REMOVE PARKING LOCK ROD SUB-ASSEMBLY 
    1. Remove the parking lock rod from the manual valve lever.
      Fig 33: Removing Parking Lock Rod From Manual Valve Lever
      GTY157832Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  25. REMOVE MANUAL VALVE LEVER SHAFT OIL SEAL 
    1. Using a screwdriver, pry out the oil seal from the transaxle.
      Fig 34: Prying Out Oil Seal From Transaxle Case
      GTY165140Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  26. SECURE AUTOMATIC TRANSAXLE ASSEMBLY 
    1. Secure the automatic transaxle assembly with the oil pump side facing up.
  27. INSPECT INPUT SHAFT END PLAY  See step  2
  28. REMOVE NO. 1 TRANSAXLE CASE PLUG 
    1. Remove the 2 plugs.
      Fig 35: Identifying No. 1 Transaxle Case Plug And O-Rings
      GTY158681Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the 2 O-rings from the 2 plugs.
  29. REMOVE TRANSAXLE HOUSING 
    1. Remove the 18 bolts.
      Fig 36: Locating Transaxle Housing Bolts
      GTY222447Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Tap on the circumference of the transaxle housing with a plastic-faced hammer to remove the transaxle housing from the transaxle case.
      NOTE:

      The differential may be accidentally removed when the transaxle housing is removed.

  30. REMOVE OIL PUMP ASSEMBLY 
    1. Remove the 7 bolts and oil pump from the transaxle.
      Fig 37: Locating Oil Pump Assembly Bolts
      GTY205666Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  31. REMOVE THRUST NEEDLE ROLLER BEARING 
    1. Remove the thrust needle roller bearing from the underdrive planetary gear.
      Fig 38: Identifying Thrust Needle Roller Bearing
      GTY157726Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  32. REMOVE NO. 2 THRUST BEARING UNDERDRIVE RACE 
    1. Remove the thrust bearing underdrive race from the underdrive planetary gear.
      Fig 39: Identifying Thrust Bearing Race
      GTY163766Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  33. REMOVE DIFFERENTIAL GEAR ASSEMBLY 
    1. Remove the differential gear from the transaxle.
      Fig 40: Removing Front Differential From Transaxle
      GTY245544Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  34. REMOVE OVERDRIVE BRAKE GASKET 
    1. Remove the 2 overdrive brake gaskets from the transaxle.
      Fig 41: Remove/Install Overdrive Brake Gaskets
      GTY157898Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  35. REMOVE FORWARD CLUTCH ASSEMBLY 
    1. Remove the forward clutch from the transaxle.
      Fig 42: Identifying Forward Clutch
      GTY164543Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the thrust bearing from the forward clutch.
      Fig 43: Identifying Thrust Bearing
      GTY163180Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  36. INSPECT PACK CLEARANCE OF FORWARD CLUTCH  See step  3
  37. REMOVE FORWARD MULTIPLE DISC CLUTCH DISC 
    1. Using a screwdriver, remove the snap ring.
      Fig 44: Removing/Installing Snap Ring
      GTY164278Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the flange, 5 discs and 5 plates from the input shaft.
      Fig 45: Identifying Flange, Discs And Plates
      GTY158656Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  38. INSPECT FORWARD MULTIPLE DISC CLUTCH DISC  See step  4
  39. REMOVE FORWARD CLUTCH RETURN SPRING SUB-ASSEMBLY 
    1. Place SST on the spring retainer and compress the return spring with a press.
      Fig 46: Removing Snap Ring
      GTY162435Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      • SST: 09350-32014 
        • 09351-32070
    2. Using a snap ring expander, remove the snap ring.
    3. Remove the forward clutch return spring sub-assembly.
      Fig 47: Placing Return Spring Onto Piston
      GTY230223Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  40. INSPECT FORWARD CLUTCH RETURN SPRING SUB-ASSEMBLY  See step  5
  41. REMOVE FORWARD CLUTCH PISTON SUB-ASSEMBLY 
    1. Place the forward clutch drum onto the oil pump.
      Fig 48: Applying Compressed Air To Oil Pump
      GTY157810Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    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 sub-assembly.

      HINT: 

      When the piston is slanted and cannot be removed, remove it by pushing down the protruding side and applying compressed air again, or using needlenose pliers (with its tips wrapped in tape).

  42. INSPECT FORWARD CLUTCH PISTON SUB-ASSEMBLY  See step  6
  43. REMOVE INPUT SHAFT OIL SEAL RING 
    1. Remove the input shaft oil seal ring from the forward clutch drum.
      Fig 49: Removing Input Shaft Oil Seal Ring
      GTY159465Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  44. REMOVE MULTIPLE DISC CLUTCH HUB 
    1. Remove the thrust needle roller bearing, multiple clutch hub, needle roller bearing and bearing race from the transaxle.
      Fig 50: Identifying Thrust Bearing, Multiple Clutch Hub, Needle Roller Bearing And Bearing Race
      GTY157899Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  45. INSPECT MULTIPLE DISC CLUTCH HUB  See step  7
  46. REMOVE UNDERDRIVE PLANETARY GEAR ASSEMBLY 
    1. Remove the bolt and parking pawl shaft clamp.
      Fig 51: Remove/Install Pawl Shaft Clamp With Bolt
      GTY163719Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the parking lock pawl shaft.
      Fig 52: Removing Parking Lock Pawl Shaft
      GTY245626Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Push the parking lock pawl.
      Fig 53: Pushing Parking Lock Pawl
      GTY227684Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      HINT: 

      Failure to do so will cause interference when the underdrive planetary gear is removed.

    4. Remove the underdrive planetary gear from the transaxle.
      Fig 54: Removing/Installing Underdrive Planetary Gear From Transaxle Case
      GTY157900Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:

      Be careful not to drop the underdrive planetary gear assembly.

    5. Remove the spring, pawl pin and parking lock pawl.
      Fig 55: Removing Spring, Pawl Pin And Parking Lock Pawl
      GTY245627Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  47. INSPECT UNDERDRIVE PLANETARY GEAR PRELOAD  See step  8
  48. REMOVE UNDERDRIVE INPUT SHAFT NUT 
    1. Using SST, secure the underdrive planetary gear.
      Fig 56: Identifying Underdrive Planetary Gear
      GTY245658Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      • SST: 09387-00050 
    2. Using SST, loosen the staked part of the nut.
      Fig 57: Locating Staked Portion Of Planetary Gear Nut
      GTY121837Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      • SST: 09930-00010 
        • 09931-00010
        • 09931-00020
    3. Clamp the underdrive planetary gear in a soft jaw vise.
      Fig 58: Clamping Underdrive Planetary Gear In Soft Jaw Vise
      GTY223785Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:

      Be careful not to damage the differential drive pinion.

    4. Using a socket wrench, remove the lock nut.
      Fig 59: Clamping Underdrive Planetary Gear In Soft Jaw Vise
      GTY245666Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  49. REMOVE CYLINDRICAL ROLLER BEARING INNER RACE 
    1. Using SST, remove the cylindrical roller bearing inner race.
      Fig 60: Removing Cylindrical Roller Bearing Inner Race
      GTY245566Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      • SST: 09950-00020 
      • SST: 09950-00030 
      • SST: 09950-60010 
        • 09951-00340
      • SST: 09950-40011 
        • 09957-04010
  50. REMOVE UNDERDRIVE PLANETARY GEAR ASSEMBLY 
    1. Using SST and a press, remove the differential drive pinion, parking lock gear, counter driven gear with underdrive planetary ring gear, and angular ball bearing.
      Fig 61: Removing Differential Drive Pinion
      GTY164686Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      • SST: 09387-00050 
    2. Clamp the underdrive planetary gear in a soft jaw vise.
    3. Using SST, remove the rear angular ball bearing from the underdrive planetary gear.
      Fig 62: Removing Rear Angular Ball Bearing
      GTY230939Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      • SST: 09950-00020 
      • SST: 09950-00030 
      • SST: 09950-60010 
        • 09951-00320
      • SST: 09950-40011 
        • 09957-04010
  51. REMOVE UNDERDRIVE PLANETARY RING GEAR 
    1. Using snap ring pliers, remove the snap ring.
      Fig 63: Removing Snap Ring
      GTY222219Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the underdrive planetary ring gear from the counter driven gear.
      Fig 64: Identifying Underdrive Planetary Ring Gear And Counter Driven Gear
      GTY202271Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  52. REMOVE UNDERDRIVE CLUTCH ASSEMBLY 
    1. Remove the underdrive clutch assembly, thrust bearing and bearing race from the transaxle.
      Fig 65: Identifying Underdrive Clutch Assembly
      GTY157901Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  53. INSPECT PACK CLEARANCE OF UNDERDRIVE CLUTCH  See step  9
  54. REMOVE NO. 1 UNDERDRIVE CLUTCH DISC 
    1. Using a screwdriver, pry out the underdrive clutch flange snap ring.
      Fig 66: Remove/Install Underdrive Clutch Flange Hole Snap Ring
      GTY245568Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the flange, 3 discs and 3 plates from the underdrive clutch drum.
      Fig 67: Inspecting Underdrive Clutch Drum Sub-Assembly
      GTY158658Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  55. INSPECT NO. 1 UNDERDRIVE CLUTCH DISC  See step  10
  56. INSPECT UNDERDRIVE CLUTCH DRUM SUB-ASSEMBLY  See step  11
  57. REMOVE UNDERDRIVE CLUTCH DRUM O-RING 
    1. Remove the underdrive clutch drum O-ring from the underdrive clutch drum.
      Fig 68: Identifying Underdrive Clutch Drum O-Ring
      GTY164662Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  58. REMOVE UNDERDRIVE CLUTCH PISTON SET 
    1. Place SST on the clutch balancer and compress the spring with a press.
      Fig 69: Removing Snap Ring
      GTY165447Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      • SST: 09350-32014 
        • 09351-32070
    2. Using a snap ring expander, remove the snap ring.
      NOTE:
      • Stop the press when the spring seat is lowered 1 to 2 mm (0.0394 to 0.0787 in.) from the snap ring groove. This prevents the spring seat from being deformed.
      • Do not expand the snap ring excessively.
    3. Remove the clutch balancer from the underdrive clutch drum.
      Fig 70: Removing Clutch Balancer From Underdrive Clutch Drum
      GTY242651Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Remove the piston return spring from the underdrive clutch drum.
      Fig 71: Identifying Return Spring From Underdrive Clutch Drum
      GTY242652Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Install the underdrive clutch to the transaxle.
      Fig 72: Inspecting Underdrive Clutch Return Spring Sub-Assembly
      GTY213002Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:

      Be careful not to damage the oil seal rings.

    6. Holding the underdrive clutch piston by hand, apply compressed air (392 kPa, 4.0 kgf/cm2 , 57 psi) to the transaxle case to remove the underdrive clutch piston.
  59. INSPECT UNDERDRIVE CLUTCH RETURN SPRING SUB-ASSEMBLY  See step  12
  60. REMOVE UNDERDRIVE ONE-WAY CLUTCH ASSEMBLY 
    1. Using a screwdriver, pry out the snap ring from the transaxle.
      Fig 73: Remove/Install Snap Ring To Transaxle Case
      GTY162350Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the one-way clutch from the transaxle.
      Fig 74: Removing Underdrive 1-Way Clutch From Transaxle Case
      GTY245553Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Remove the outer race retainer from the one-way clutch.
      Fig 75: Identifying Outer Race Retainer
      GTY210825Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  61. REMOVE NO. 2 UNDERDRIVE CLUTCH DISC 
    1. Using a screwdriver, pry out the snap ring.
      Fig 76: Removing/Installing Snap Ring
      GTY224662Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the flange, 3 discs and 3 plates from the transaxle.
      Fig 77: Identifying Flange, Discs And Plates
      GTY157772Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  62. INSPECT NO. 2 UNDERDRIVE CLUTCH DISC  See step  13
  63. REMOVE UNDERDRIVE BRAKE RETURN SPRING SUB-ASSEMBLY 
    1. Using SST, a snap ring expander and press, remove the snap ring and underdrive brake return spring.
      Fig 78: Removing Snap Ring From Transaxle
      GTY165972Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      • SST: 09387-00020 
  64. INSPECT UNDERDRIVE BRAKE RETURN SPRING SUB-ASSEMBLY  See step  14
  65. REMOVE NO. 1 TRANSAXLE CASE PLUG 
    1. Remove the 2 plugs from the transaxle rear cover.
      Fig 79: Identifying No. 1 Transaxle Case Plug
      GTY158682Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the 2 O-rings from the 2 plugs.
  66. REMOVE TRANSAXLE REAR COVER SUB-ASSEMBLY 
    1. Remove the 11 bolts.
      Fig 80: Removing Bolts
      GTY164697Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Tap in the circumference of the rear cover with a plastic-faced hammer to remove the transaxle rear cover from the transaxle.
      Fig 81: Identifying Oil Seal Rings
      GTY217121Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Remove the 2 oil seal rings from the transaxle rear cover.
    4. Using a T30 "TORX" socket wrench, remove the 2 screws and transaxle rear cover plate.
      Fig 82: Identifying Bolts And Transaxle Rear Cover Plate
      GTY162474Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Using SST, remove the needle-roller bearing from the transaxle rear cover.
      • SST: 09387-00041 
        • 09387-01040
        • 09387-01010
        • 09387-01030
      Fig 83: Removing Needle-Roller Bearing From Transaxle Rear Cover
      GTY157824Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  67. REMOVE BRAKE APPLY TUBE 
    1. Remove the bolt, clamp and brake apply tube.
      Fig 84: Removing/Installing Apply Tubes
      GTY163425Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the brake apply tube from the clamp.
  68. REMOVE FRONT CLUTCH APPLY TUBE 
    1. Remove the front clutch apply tube from the clamp.
  69. REMOVE NO. 1 GOVERNOR APPLY GASKET 
    1. Using a screwdriver, remove the 2 apply gaskets.
      Fig 85: Locating Apply Gaskets
      GTY164589Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  70. REMOVE DIRECT CLUTCH ASSEMBLY 
    1. Remove the thrust bearing and direct clutch from the transaxle.
      Fig 86: Identifying Thrust Bearing And Direct Clutch
      GTY162523Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the bearing race from the direct clutch.
      Fig 87: Identifying Bearing Race
      GTY245571Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  71. INSPECT PACK CLEARANCE OF DIRECT CLUTCH  See step  15
  72. REMOVE DIRECT MULTIPLE DISC CLUTCH DISC 
    1. Using a screwdriver, pry out the snap ring from the direct clutch drum.
      Fig 88: Remove/Install Snap Ring
      GTY166467Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the flange, 3 discs and 3 plates from the direct clutch drum.
      Fig 89: Identifying Flange, Discs And Plates
      GTY164144Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  73. INSPECT DIRECT MULTIPLE DISC CLUTCH DISC  See step  16
  74. REMOVE DIRECT CLUTCH RETURN SPRING SUB-ASSEMBLY 
    1. Place SST on the clutch balancer and compress the spring with a press.
      Fig 90: Removing/Installing Snap Ring
      GTY157814Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      • SST: 09387-00020 
    2. Using a snap ring expander, remove the snap ring from the direct clutch drum.
      NOTE:
      • Stop the press when the spring seat is lowered 1 to 2 mm (0.0394 to 0.0787 in.) from the snap ring groove. This prevents the spring seat from being deformed.
      • Do not expand the snap ring excessively.
    3. Remove the clutch balancer from the direct clutch drum.
      Fig 91: Removing Clutch Balancer From Direct Clutch Drum
      GTY167001Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Remove the return spring from the direct clutch drum.
      Fig 92: Removing Piston Return Spring From Direct Clutch Drum
      GTY157753Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Install the direct clutch drum on the transaxle rear cover.
      Fig 93: Applying Compressed Air To Transaxle Rear Cover
      GTY157754Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    6. Holding the direct clutch piston by hand, apply compressed air (392 kPa, 4.0 kgf*cm2 , 57 psi) to the transaxle rear cover to remove the direct clutch piston.
  75. INSPECT DIRECT CLUTCH RETURN SPRING SUB-ASSEMBLY  See step  17
  76. REMOVE REAR PLANETARY SUN GEAR ASSEMBLY 
    1. Remove the rear planetary sun gear from the transaxle.
      Fig 94: Identifying Rear Planetary Sun Gear
      GTY157902Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the thrust bearing from the rear planetary sun gear.
      Fig 95: Identifying Rear Planetary Sun Gear Thrust Bearing
      GTY157821Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Remove the No. 2 washer from the rear planetary sun gear.
      Fig 96: Identifying No. 1 Planetary Carrier Thrust Washer
      GTY245587Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  77. REMOVE ONE-WAY CLUTCH ASSEMBLY 
    1. Remove the one-way clutch and thrust bearing from the transaxle.
      Fig 97: Remove/Install 1-Way Clutch And Thrust Bearing
      GTY225199Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the inner race from the one-way clutch.
      Fig 98: Removing 1-Way Clutch Inner Race From 1-Way Clutch
      GTY163764Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  78. REMOVE ONE-WAY CLUTCH OUTER SLEEVE 
    Fig 99: Removing 1-Way Clutch Sleeve Outer From Transaxle Case
    GTY166183Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  79. REMOVE 2ND BRAKE CLUTCH DISC 
    1. Using a screwdriver, remove the snap ring.
      Fig 100: Identifying Flange, Discs And Plates
      GTY158653Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the flange, 3 discs and 3 plates from the transaxle.
  80. INSPECT 2ND BRAKE CLUTCH DISC  See step  18
  81. REMOVE 2ND BRAKE PISTON ASSEMBLY 
    1. Using a screwdriver, remove the snap ring.
      Fig 101: Removing Snap Ring
      GTY164047Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the 2nd brake piston from the transaxle.
      Fig 102: Removing 2nd Brake Piston
      GTY163044Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  82. REMOVE 2ND BRAKE PISTON RETURN SPRING SUB-ASSEMBLY 
    1. Using SST and a press, remove the snap ring from the 2nd brake piston.
      Fig 103: Removing/Installing Snap Ring
      GTY165904Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      • SST: 09387-00060 
    2. Using a screwdriver, pry out the snap ring.
    3. Remove the piston return spring.
      Fig 104: Identifying Piston Return Spring
      GTY245581Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  83. INSPECT 2ND BRAKE PISTON RETURN SPRING SUB-ASSEMBLY  See step  19
  84. REMOVE 2ND BRAKE PISTON 
    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 105: Removing 2nd Brake Piston
      GTY215162Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  85. REMOVE 2ND BRAKE PISTON O-RING 
    1. Remove the 2 O-rings from the 2nd brake piston.
      Fig 106: Identifying 2nd Brake Piston O-Ring
      GTY245582Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  86. REMOVE REAR PLANETARY GEAR ASSEMBLY 
    1. Using a screwdriver, pry out the snap ring.
      Fig 107: Remove/Install Snap Ring
      GTY162582Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the rear planetary gear from the transaxle.
      Fig 108: Identifying Rear Planetary Gear
      GTY166856Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Remove the No. 1 washer from the rear planetary gear.
      Fig 109: Identifying Planetary Carrier Thrust Washer
      GTY157835Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Remove the bearing race from the rear planetary gear.
      Fig 110: Removing/Installing Rear Planetary Gear Assembly
      GTY163489Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  87. REMOVE INPUT SUN GEAR 
    1. Remove the 2 thrust bearings, bearing race and input sun gear from the transaxle.
      Fig 111: Identifying Thrust Bearings, Bearing Race And Input Sun Gear
      GTY163451Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  88. REMOVE FRONT PLANETARY GEAR ASSEMBLY 
    1. Using a chisel and a hammer, unstake the lock washer.
      Fig 112: Unstaking Lock Washer
      GTY164309Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:

      Push down all of the washer claws. Otherwise SST cannot be fully pressed against and loosen the nut.

    2. Using SST, remove the nut.
      Fig 113: Removing/Installing Front Planetary Gear Nut
      GTY149342Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      • SST: 09387-00030 
      • SST: 09387-00080 
    3. Using SST and a press, remove the front planetary gear from the counter drive gear.
      Fig 114: Removing Front Planetary Gear
      GTY166570Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      • SST: 09950-60010 
        • 09951-00450
    4. Remove the front planetary gear from the brake hub.
      Fig 115: Removing Front Planetary Gear From Brake Hub
      GTY157745Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  89. REMOVE FRONT PLANETARY RING GEAR 
    1. Using a screwdriver, remove the snap ring and front planetary ring gear from the brake hub.
      Fig 116: Remove/Install Front Planetary Ring Gear Snap Ring
      GTY157796Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  90. REMOVE 1ST AND REVERSE BRAKE CLUTCH DISC 
    1. Remove the flange, 5 discs and 5 plates from the transaxle case.
      Fig 117: Identifying Flange, Discs And Plates
      GTY157783Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  91. INSPECT 1ST AND REVERSE BRAKE CLUTCH DISC  See step  20
  92. REMOVE 1ST AND REVERSE BRAKE RETURN SPRING SUB-ASSEMBLY 
    1. Using SST, a press and snap ring expander, remove the snap ring and 1st and reverse brake return spring sub-assembly.
      Fig 118: Compressing Return Spring Using SST
      GTY130506Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      • SST: 09387-00070 
      NOTE:
      • Stop the press when the spring seat is lowered 1 to 2 mm (0.0394 to 0.0787 in.) from the snap ring groove. This prevents the spring seat from being deformed.
      • Do not expand the snap ring excessively.
  93. INSPECT 1ST AND REVERSE BRAKE RETURN SPRING SUB-ASSEMBLY  See step  21
  94. REMOVE 1ST AND REVERSE BRAKE PISTON 
    1. Apply compressed air (392 kPa, 4.0 kgf/cm2 , 57 psi) to the transaxle case to remove the 1st and reverse brake piston.
      Fig 119: Applying Compressed Air To Transaxle
      GTY165857Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      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 spatter ATF when applying compressed air.
    2. Remove the 2 O-rings from the 1st and reverse brake piston.
      Fig 120: Removing O-Rings
      GTY165484Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  95. REMOVE COUNTER DRIVE GEAR 
    1. Using SST and a press, remove the counter drive gear from the transaxle case.
      Fig 121: Pressing Out Counter Drive Gear
      GTY157903Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      • SST: 09950-60010 
        • 09951-00580
      • SST: 09950-70010 
        • 09951-07100
    2. As shown in the illustration, tighten 2 service bolts evenly and make a clearance of approximately 20.0 mm (0.787 in.) between the counter drive gear and the inner race.
      Fig 122: Tightening Bolts Evenly And Checking Clearance Between Counter Drive Gear And Inner Race
      GTY149343Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Using SST, remove the tapered roller bearing.
      Fig 123: Removing Tapered Roller Bearing
      GTY157905Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      • SST: 09950-60010 
        • 09951-00580
      • SST: 09950-00020 
      • SST: 09950-00030 
    4. Using a brass bar and a hammer, tap out the 2 bearing outer races.
      Fig 124: Taping Out Bearing Outer Races
      GTY157823Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  96. REMOVE COUNTER DRIVE GEAR HOLE SNAP RING 
    1. Using a screwdriver, pry out the snap ring from the transaxle.
      Fig 125: Removing/Installing Snap Ring
      GTY157906Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  97. REMOVE NO. 2 BREATHER PLUG 
  98. REMOVE UNDERDRIVE BRAKE PISTON 
    1. Apply compressed air (392 kPa, 4.0 kgf/cm2 , 57 psi) to the transaxle case to remove the underdrive brake piston.
      Fig 126: Applying Compressed Air
      GTY229741Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      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 spatter ATF when applying compressed air.
    2. Remove the 2 O-rings from the underdrive brake piston.
      Fig 127: Removing O-Rings From Underdrive Brake Piston
      GTY157822Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Using SST, remove the needle-roller bearing from the transaxle.
      Fig 128: Removing Needle-Roller Bearing
      GTY219006Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      • SST: 09387-00041 
        • 09387-01010
        • 09387-01030
        • 09387-01040
  99. REMOVE UNDERDRIVE CLUTCH DRUM OIL SEAL RING 
    1. Remove the 2 oil seal rings from the transaxle.
      Fig 129: Remove/Install Underdrive Clutch Drum Oil Seal Ring
      GTY157836Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  100. REMOVE UNDERDRIVE CYLINDRICAL ROLLER BEARING 
    1. Using SST, remove the cylindrical roller bearing from the transaxle.
      Fig 130: Removing Cylindrical Roller Bearing
      GTY166434Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      • SST: 09514-35011 
  101. REMOVE UNDERDRIVE OUTPUT SHAFT OIL SEAL RING 
    1. Remove the oil seal ring from the transaxle housing.
      Fig 131: Identifying Oil Seal Ring
      GTY162174Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  102. REMOVE DIFFERENTIAL GEAR LUBE APPLY TUBE 
    1. Remove the bolt, clamp and apply tube from the transaxle.
      Fig 132: Remove/Install Differential Gear Lube Apply Tube
      GTY157907Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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