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Home >> Toyota >> 1988 >> Land Cruiser >> Repair and Diagnosis >> Transmission >> Automatic Trans >> Overhaul - A-440F >> Transmission Disassembly

Transmission Disassembly

  1. Disconnect 4 connectors and remove transmission wire harness. Using 2 screwdrivers, pry out breather plug. Remove control shaft lever. Remove oil cooler pipe assemblies.
  2. Remove neutral start switch. Remove oil cooler unions. Remove ATF temperature sensor. Remove throttle cable clamp. Remove transmission housing.
  3. Remove oil pan protector. DO NOT  turn transmission over or control valve assembly will be contaminated with any foreign matter at bottom of oil pan. Remove oil pan and gasket. Remove magnets from oil pan.
    CAUTION: Note control valve assembly bolts length and location. Proper length bolts must be installed in correct locations to prevent transaxle case damage.
  4. Remove lock-up relay valve body plate and gasket. DO NOT  drop lock-up relay valve pins. Using large screwdriver, remove oil tube. Temporarily install lock-up relay valve body plate with 4 short bolts. Remove oil strainer and gasket. Disconnect throttle cable from cam and remove control valve assembly. See CONTROL VALVE ASSEMBLY  table under ON-VEHICLE SERVICE.
  5. Remove center support apply gaskets. Using 10 mm socket, remove throttle cable by pushing retainer part of throttle cable. Remove rear clutch accumulator piston and spring by applying compressed air to oil hole. See Fig 1. Remove Overdrive (OD) brake accumulator piston together with 2nd brake accumulator piston by applying compressed air to oil hole. See Fig 1. Remove OD brake and 2nd brake accumulator springs. Identify each accumulator piston and spring for reassembly reference.
    Fig 1: Removing Accumulator Pistons & Springs
    G93B25222Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  6. Check thrust clearance of OD input shaft OD planetary gear. Push OD input shaft toward rear of transmission by applying a force of 11-22 lbs. (5-10 kg). Measure thrust clearance of input shaft. Standard thrust clearance should be .0157-.0354" (.400-.900 mm). Maximum thrust clearance is .035" (.90 mm).
  7. Remove oil pump retaining bolts. Using Puller (09350-06140), remove oil pump and gasket. Remove 2 races and thrust bearing from OD direct clutch drum or oil pump.
  8. Place Plate (09350-06090) on installation surface of oil pump. Using calipers, measure distance between top of plate and clutch drum. Record reading for reassembly reference. Remove OD planetary gear, OD direct clutch and one-way clutch assembly. Remove bearing and race from OD planetary gear or ring gear flange.
  9. Remove OD planetary ring gear assembly from OD case. Remove thrust bearing and race from OD case or ring gear flange.
  10. Remove transfer No. 2 case cover. See the appropriate TRANSFER CASE article in TRANSFER CASES for detailed information.
  11. Check thrust clearance of input shaft front clutch drum. Push transmission output shaft toward front of transmission by applying a force of 11-22 lbs. (5-10 kg). Push OD case toward rear of transmission by applying a force of 11-20 lbs. (5-10 kg). Using Extension Bar (09350-06130) and dial indicator, measure thrust clearance of input shaft. Standard thrust clearance should be .0118-.0276" (.300-.700 mm). Maximum thrust clearance is .0276" (.700 mm).
  12. Using screwdriver, remove snap ring. Remove OD case set bolts. Using Puller (09350-06140), remove OD case assembly. Remove "O" rings from oil holes in OD case. Remove oil seal ring from input shaft. Remove races, thrust bearing and spacer from front clutch drum or OD case. See Fig 5.
  13. Place Plate (09350-06090) on installation surface of oil pump. Measure distance between top of plate and front clutch drum. Record reading for reassembly reference. Remove front clutch. Remove races and thrust bearing from rear clutch drum or front clutch hub. Insert 2 wires into flukes of clutch discs. Remove rear clutch.
  14. Check thrust clearance of center support. Push transmission output shaft toward front of transmission by applying a force of 11-22 lbs. (5-10 kg). Push center support toward rear of transmission by applying a force of 11-22 lbs. (5-10 kg), then pull with same amount of force. Place Plate (09350-06090) on center support. Using calipers, measure distance "A" between top of plate and thrust washer on front planetary gear. Using calipers, measure thickness "B" of plate. Record readings for reassembly reference. Remove 3 center support set bolts. Using Puller (09350-06140), remove center support. Remove "O" rings from center support oil holes. See Figure.
  15. Turn center support over together with thrust washer and place on a flat surface. Insert calipers into thrust washer hole, measure distance "C" between thrust washer hole and flat surface. Center support thrust clearance is "A" - ("B" + "C"). Standard thrust clearance should be .0118-.0276" (.300-.700 mm). Maximum thrust clearance is .0354" (.900 mm). Remove thrust washer from center support.
  16. Remove transfer component parts. See appropriate TRANSFER CASE article in TRANSFER CASES. Remove transfer adapter and output shaft rear bearing. Remove transfer adapter bolts. Using Puller (09350-06140), remove transfer adapter with rear bearing. Remove gasket.
  17. Remove output shaft spacer. Remove governor body assembly. Remove thrust washer from planetary gear. Remove snap ring. Remove planetary gears, one-way clutch and output shaft.
  18. Using Spring Compressor (09350-06130) and dial indicator, measure piston stroke of 1st and reverse brake piston by applying compressed air. See Fig 2. Piston stroke should be .1299-.1496" (3.30-3.80 mm). If piston stroke is not within specification, inspect discs.
    Fig 2: Checking 1st & Reverse Brake Piston
    G93C25223Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  19. Remove snap ring. Remove flange, 6 discs, 6 plates and cushion plate. Set Spring Compressor (09350-06030) on spring retainer, compress return spring. Remove snap ring. Remove piston return spring. Hold 1st and reverse brake piston with hand, remove 1st and reverse brake piston by applying compressed air into oil hole of transmission case. If piston does not pop out with compressed air, lift piston out with needle-nose pliers. Remove 2 "O" rings from piston.
  20. Remove front clutch accumulator cover, gaskets and plate. Remove accumulator piston and spring by applying compressed air to oil hole. Remove "O" rings from accumulator piston.
  21. Remove transmission rear cover and gasket. Remove manual valve lever, shaft and oil seals. Using a chisel, cut off spacer and remove from shaft. Tap out pin with a pin punch. Pull manual valve lever shaft out through case. Remove manual valve lever, parking lock rod, 2 plate washers and wave washer. Disconnect parking lock rod from manual valve lever. Using a screwdriver, pry out 2 oil seals. See Fig 3, Fig 4, and Fig 5 .
Fig 3: Exploded View Of External Components
G93D25224Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Fig 4: Exploded View Of Center Components
G93E25225Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Fig 5: Exploded View Of Internal Components
G93F25226Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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