Automatic Transmission Unit: Disassembly: Disassembly
- REMOVE TRANSMISSION CONTROL SHAFT LEVER RH
- Remove the nut, spring washer and transmission control shaft lever RH.
- REMOVE PARK/NEUTRAL POSITION SWITCH ASSEMBLY
- Using a screwdriver, bend the tabs of the lock washer.
- Remove the nut and lock washer.
- Remove the bolt and park/neutral position switch assembly.
- REMOVE OIL COOLER TUBE UNION
- Remove the 2 oil cooler tube elbows.
- Remove the O-rings from the oil cooler tube elbows.
- REMOVE NO. 1 BREATHER PLUG
- REMOVE AUTOMATIC TRANSMISSION OIL PAN SUB-ASSEMBLY NOTE:
Do not turn the transmission over as this will contaminate the valve body with foreign matter located at the bottom of the pan.
- Remove the overflow plug and gasket.
- Remove the drain plug and gasket.
- Remove the 9 bolts, automatic transmission oil pan and gasket.
- Examine the particles in the pan.
- Remove the magnets from the oil pan. Use the removed magnets to collect any steel chips. Look carefully at the chips and particles in the pan and on the magnet to anticipate the type of wear which might be found in the transmission.
Steel (magnetic): bearing, gear and plate wear
Brass (non-magnetic): bush wear
- Remove the magnets from the oil pan. Use the removed magnets to collect any steel chips. Look carefully at the chips and particles in the pan and on the magnet to anticipate the type of wear which might be found in the transmission.
- REMOVE VALVE BODY OIL STRAINER ASSEMBLY
- Remove the 4 bolts and valve body oil strainer assembly from the transmission valve body assembly.
- Remove the O-ring from the valve body oil strainer assembly.
- REMOVE TRANSMISSION VALVE BODY ASSEMBLY
- Remove the bolt, lock plate and ATF temperature sensor.
- Remove the oil pressure switch connector.
- Disconnect the 9 connectors from the solenoid valves.
- Remove the bolt, detent spring cover and detent spring.
- Remove the 17 bolts and transmission valve body assembly.NOTE:
Do not drop the check ball body or spring.
- Disconnect the lever pin from the manual valve.NOTE:
Do not drop the manual valve.
- REMOVE CHECK BALL BODY
- Remove the check ball body and spring.
- REMOVE TRANSMISSION WIRE
- Disconnect the 3 connectors from the 3 speed sensors.
- Remove the bolt and pull out the transmission wire.
- REMOVE SPEED SENSOR
- Remove the 2 bolts and 2 speed sensors (NC3 and SP2).
- Using a T30 "TORX" wrench, remove the bolt and speed sensor NT.
- REMOVE AUTOMATIC TRANSMISSION CASE PLUG
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
- Remove the automatic transmission case plug and O-ring.
- REMOVE PARKING LOCK PAWL BRACKET
- Remove the 3 bolts and parking lock pawl bracket.
- REMOVE PARKING LOCK ROD SUB-ASSEMBLY
- Disconnect the parking lock rod from the manual valve lever.
- REMOVE PARKING LOCK PAWL SHAFT
- Pull out the parking lock pawl shaft from the front side, and then remove the parking lock pawl and spring.
- Remove the E-ring from the shaft.
- REMOVE MANUAL VALVE LEVER SUB-ASSEMBLY
- Using a screwdriver and hammer, cut off the spacer and remove it from the manual valve lever shaft.
- Using a pin punch and hammer, tap out the spring pin.
HINT:
Slowly tap out the spring pin so that it does not fall into the transmission case.
- Pull the manual valve lever shaft out through the case and remove the manual valve lever.
- REMOVE MANUAL VALVE LEVER SHAFT OIL SEAL
- REMOVE OIL PUMP ASSEMBLY
- Remove the 11 bolts from the transmission case.
- Pull out the oil pump assembly.
NOTE:
Do not damage the oil pump assembly.
- Remove the O-ring from the oil pump assembly.
- REMOVE OVERDRIVE AND REVERSE CLUTCH DRUM SUB-ASSEMBLY AND FRONT PLANETARY GEAR ASSEMBLY WITH NO. 1 BRAKE DISC SET
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
- Remove the overdrive and reverse clutch drum sub-assembly and front planetary gear assembly with No. 1 brake disc set from the transmission case.
- Remove the thrust needle roller bearing and thrust bearing race.
- REMOVE NO. 1 BRAKE DISC SET
- Remove the 5 plates, 5 discs and No. 1 brake flange.
- INSPECT NO. 1 BRAKE DISC See step 1
- REMOVE FRONT PLANETARY GEAR ASSEMBLY
- Remove the front planetary gear assembly with the front planetary sun gear from the overdrive and reverse clutch drum sub-assembly.
- Remove the 3 clutch drum oil seal rings.
- Remove the planetary carrier thrust washer.
- Remove the 2 clutch drum oil seal rings.
- Remove the planetary sun gear.
- INSPECT FRONT PLANETARY GEAR ASSEMBLY See step 2
- REMOVE OVERDRIVE CLUTCH DISC SET
- INSPECT OVERDRIVE CLUTCH DISC See step 3
- REMOVE REVERSE CLUTCH DISC SET
- INSPECT REVERSE CLUTCH DISC See step 4
- REMOVE REVERSE CLUTCH PISTON
- Place SST on the reverse clutch balancer and compress the reverse clutch return spring with a press.
- SST: 09380-50010
- Using SST, remove the snap ring.
- SST: 09350-30020
- 09350-07070
- SST: 09350-30020
- Remove the reverse clutch balancer and reverse clutch return spring sub-assembly from the reverse clutch drum.
- Hold the reverse clutch piston and apply compressed air to the oil hole of the reverse clutch drum to remove the reverse clutch piston.TEXT IN ILLUSTRATION
*1 Oil Hole - Remove the O-ring from the reverse clutch piston.
- Place SST on the reverse clutch balancer and compress the reverse clutch return spring with a press.
- INSPECT REVERSE CLUTCH RETURN SPRING SUB-ASSEMBLY See step 5
- REMOVE REVERSE CLUTCH DRUM SUB-ASSEMBLY
- Remove the reverse clutch drum sub-assembly from the overdrive direct clutch drum sub-assembly.
HINT:
The reverse clutch drum is easier to remove if a hole snap ring is installed. Use the hole snap ring from the "REMOVE REVERSE CLUTCH DISC SET" procedure.
- Remove the 3 O-rings from the reverse clutch drum.
- Remove the reverse clutch drum sub-assembly from the overdrive direct clutch drum sub-assembly.
- REMOVE OVERDRIVE DIRECT CLUTCH PISTON SUB-ASSEMBLY
- Place SST on the No. 3 clutch balancer and compress the overdrive clutch return spring with a press.
- SST: 09380-50010
- Using SST, remove the snap ring.
- SST: 09350-30020
- 09350-07070
- SST: 09350-30020
- Remove the No. 3 clutch balancer and overdrive clutch return spring.
- Hold the overdrive direct clutch piston and apply compressed air to the oil hole of the drum to remove the overdrive direct clutch piston.TEXT IN ILLUSTRATION
*1 Oil Hole - Remove the O-ring from the No. 3 clutch balancer.
- Remove the O-ring from the overdrive direct clutch piston sub-assembly.
- Remove the O-ring from the overdrive direct clutch drum sub-assembly.
- Place SST on the No. 3 clutch balancer and compress the overdrive clutch return spring with a press.
- INSPECT OVERDRIVE CLUTCH RETURN SPRING SUB-ASSEMBLY See step 6
- INSPECT OVERDRIVE DIRECT CLUTCH DRUM SUB-ASSEMBLY See step 7
- REMOVE FORWARD MULTIPLE DISC CLUTCH SUB-ASSEMBLY WITH FRONT PLANETARY RING GEAR
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
- Remove the forward multiple disc clutch with front planetary ring gear, the thrust needle roller bearing and the thrust bearing race from the transmission case.
- Using needle-nose pliers, detach the snap ring and remove the front planetary ring gear from the forward clutch drum.
- REMOVE FORWARD MULTIPLE CLUTCH DISC SET
- INSPECT FORWARD MULTIPLE DISC CLUTCH CLUTCH DISC See step 8
- REMOVE FORWARD CLUTCH PISTON
- Place SST on the No. 1 clutch balancer and compress the forward clutch return spring with a press.
- SST: 09380-50010
- Using SST, remove the snap ring.
- SST: 09350-30020
- 09350-07070
- SST: 09350-30020
- Remove the No. 1 clutch balancer and forward clutch return spring sub-assembly from the forward clutch drum sub-assembly.
- Remove the O-ring from the No. 1 clutch balancer.
- Hold the forward clutch piston and apply compressed air to the oil hole of the drum to remove the forward clutch piston.TEXT IN ILLUSTRATION
*1 Oil Hole - Remove the 2 O-rings from the forward clutch piston.
- Place SST on the No. 1 clutch balancer and compress the forward clutch return spring with a press.
- INSPECT FORWARD CLUTCH RETURN SPRING SUB-ASSEMBLY See step 9
- INSPECT FORWARD CLUTCH DRUM SUB-ASSEMBLY See step 10
- REMOVE MULTIPLE DISC CLUTCH CLUTCH HUB
- Remove the multiple disc clutch clutch hub from the transmission case.
- Remove the thrust bearing race and thrust needle roller bearing from the transmission case.
- REMOVE SUN GEAR INPUT DRUM SUB-ASSEMBLY
- Remove the sun gear input drum, thrust needle roller bearing and thrust bearing race from the transmission case.
- INSPECT SUN GEAR INPUT DRUM SUB-ASSEMBLY See step 11
- REMOVE REAR PLANETARY SUN GEAR ASSEMBLY
- Remove the rear planetary sun gear assembly and thrust bearing race from the transmission case.
- REMOVE 1-WAY CLUTCH OUTER RACE WITH NO. 1 1-WAY CLUTCH
- Using SST, remove the snap ring from the transmission case.
- SST: 09350-30020
- 09350-07060
- SST: 09350-30020
- Remove the 1-way clutch outer race with No. 1 1-way clutch.
- Using SST, remove the snap ring from the transmission case.
- INSPECT REAR PLANETARY SUN GEAR ASSEMBLY See step 12
- REMOVE REAR PLANETARY GEAR ASSEMBLY
- Remove the thrust needle roller bearing, rear planetary gear assembly and thrust bearing race from the transmission case.
- INSPECT NO. 1 1-WAY CLUTCH See step 14
- REMOVE NO. 1 1-WAY CLUTCH
- Remove the 2 snap rings from the 1-way clutch outer race.
- INSPECT REAR PLANETARY GEAR ASSEMBLY See step 13
- REMOVE NO. 2 BRAKE DISC SET
- Remove the brake plate, 4 No. 2 brake discs, 3 No. 2 brake plates and No. 2 brake flange.
- INSPECT NO. 2 BRAKE DISC See step 15
- REMOVE DIRECT CLUTCH DRUM SUB-ASSEMBLY WITH REAR PLANETARY RING GEAR AND OUTPUT SHAFT SUB-ASSEMBLY
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
- Remove the 2 thrust needle roller bearings, the 2 thrust bearing races and the direct clutch drum with rear planetary ring gear and output shaft from the transmission case.
- REMOVE REAR PLANETARY RING GEAR
- Using needle-nose pliers, detach the snap ring and disconnect the rear planetary ring gear from the output shaft.
- DISCONNECT DIRECT CLUTCH DRUM SUB-ASSEMBLY
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
- Disconnect the direct clutch drum from the output shaft and remove the thrust needle roller bearing and thrust bearing race from the output shaft.
- Remove the 3 oil seal rings from the output shaft.
- Remove the 2 oil seal rings from the direct clutch drum.
- REMOVE NO. 2 CLUTCH DISC SET
- INSPECT NO. 2 CLUTCH DISC See step 16
- REMOVE DIRECT CLUTCH PISTON
- Place SST on the No. 2 clutch balancer and compress the direct clutch return spring with a press.
- SST: 09387-00020
- Using SST, remove the snap ring.
- SST: 09350-30020
- 09350-07070
- SST: 09350-30020
- Remove the No. 2 clutch balancer and direct clutch return spring sub-assembly from the direct clutch drum sub-assembly.
- Remove the O-ring from the No. 2 clutch balancer.
- Hold the direct clutch piston and apply compressed air to the oil hole of the direct clutch drum to remove the direct clutch piston.
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
TEXT IN ILLUSTRATION*1 Oil Hole - Remove the O-ring from the direct clutch piston.
- Remove the O-ring from the direct clutch drum sub- assembly.
- Place SST on the No. 2 clutch balancer and compress the direct clutch return spring with a press.
- INSPECT DIRECT CLUTCH RETURN SPRING SUB-ASSEMBLY See step 17
- REMOVE TRANSFER CASE ADAPTER REAR OIL SEAL
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
- REMOVE OUTPUT SHAFT REAR RADIAL BALL BEARING
- Using snap ring pliers, remove the snap ring from the transmission case.
- Using SST, remove the output shaft rear radial ball bearing.
- SST: 09308-00010
- REMOVE NO. 2 BRAKE PISTON
- Set SST on the No. 2 brake piston return spring sub-assembly, tighten SST and compress the No. 2 brake piston return spring sub-assembly.
- SST: 09380-50010
- Using SST, remove the snap ring and the No. 2 brake piston return spring.
- SST: 09350-30020
- 09350-07070
- SST: 09350-30020
- Hold the No. 2 brake piston and apply compressed air to the oil hole of the transmission case to remove the No. 2 brake piston.
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
TEXT IN ILLUSTRATION*1 Oil Hole - Remove the 3 O-rings from the No. 2 brake piston.
- Set SST on the No. 2 brake piston return spring sub-assembly, tighten SST and compress the No. 2 brake piston return spring sub-assembly.
- INSPECT NO. 2 BRAKE PISTON RETURN SPRING SUB-ASSEMBLY See step 18