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Transaxle Disassembly

  1. Remove transfer case. Remove 2 bolts and 6 nuts. Using plastic hammer, drive transfer case from transaxle. Pull transfer case straight up to remove from transaxle. Remove round gasket and intermediate shaft. Remove nut, washer and control shift lever. Using a screwdriver, unstake lock tab. Remove 2 bolts and nut, and remove park/neutral position switch. See Fig 2.
  2. Remove oil line union and elbow. Remove and discard "O" rings from union and elbow. Remove input turbine and counter gear speed sensors from top of transaxle. See Fig 1. Remove and discard speed sensor "O" rings. Remove transaxle test plug from transaxle case. See Fig 3. Remove solenoid connector bolt located above park/neutral position switch. DO NOT try to remove solenoid connector from transaxle case at this time.
  3. Place transaxle on wooden blocks. Remove 18 bolts, oil pan and gasket. Disconnect 5 shift solenoid connectors. Remove bolts, clamps and fluid temperature sensor. See Fig 4. Remove transaxle wiring harness with solenoid connector from transaxle case. Remove 3 bolts and oil strainer. Remove and discard gasket from oil strainer.
  4. Remove 17 valve body bolts. Note bolt length and location for reassembly reference. See Figure. Remove valve body assembly.
  5. Remove 3 apply gaskets, check ball body and spring. See Fig 5. Remove brake drum gasket located near 3 apply gaskets. See Fig 2. Remove underdrive clutch accumulator spring. Using 57 psi (4 kg/cm2 ) of compressed air applied to transaxle case, remove underdrive clutch accumulator piston. See Fig 6. Cover piston with shop towel during removal.
    Fig 1: Locating Transfer Assembly & Speed Sensors
    G00182310Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    Fig 2: Exploded View Of Transaxle External Components
    G00011241Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    Fig 3: Locating Transaxle Test Plug
    G00011240Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    Fig 4: Locating Fluid Temperature Sensor & Solenoid Connectors
    G00011242Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    Fig 5: Locating Check Ball Body & Spring, & Apply Gaskets (3)
    G00011243Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    Fig 6: Removing Underdrive Clutch Accumulator Piston
    G00011244Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  6. Using 57 psi (4 kg/cm2 ) of compressed air applied to transaxle case, remove forward clutch accumulator piston and spring, and underdrive brake accumulator piston. Cover pistons with shop towel during removal. See Fig 7 and Fig 8 .
  7. Using needle nose pliers, remove manual valve lever retainer spring. Remove 2 bolts, manual detent spring and cover. See Fig 2. Remove 2 bolts and parking lock pawl bracket. Using a hammer and chisel, unstake and remove spacer. Using a pin punch and hammer, drive out roll pin. Ensure pin does not fall into transaxle case.
  8. Remove manual valve lever shaft and manual valve lever. Remove parking lock pawl rod from manual valve lever. Using a screwdriver, remove shaft oil seal. See Fig 2. Position transaxle case with oil pump assembly facing upward.
    CAUTION: Use caution when removing transaxle housing. Differential assembly may attach to transaxle housing during removal.
  9. Using a dial indicator, measure input shaft end play. See Fig 9. End play should be .010-.049" (.26-1.25 mm). Remove 16 transaxle housing bolts. Note bolt length and location during removal for reassembly reference. See Fig 10.
    Fig 7: Removing Forward Clutch Accumulator Piston
    G00011245Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    Fig 8: Removing Underdrive Brake Accumulator Piston
    G00011246Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    Fig 9: Measuring Input Shaft End Play
    G00011247Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    Fig 10: Removing & Installing Transaxle Housing Bolts
    G00011248Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  10. Remove 7 oil pump bolts and oil pump. Remove thrust bearing and bearing race from underdrive planetary gear assembly. Remove differential assembly. See Fig 13. Remove 2 apply gaskets from front of transaxle case. See Fig 11. Remove forward clutch from transaxle case. Remove multiple clutch hub and needle roller bearing from transaxle case. See Fig 12.
  11. Remove one bolt and parking lock pawl clamp. See Fig 13. Remove parking lock pawl shaft. Push parking lock pawl toward transaxle case to prevent interference during underdrive planetary gear assembly removal. See Fig 14. Using both hands, remove underdrive planetary gear assembly. DO NOT allow planetary gear assembly to separate.
    Fig 11: Removing 2 Apply Gaskets
    G00182268Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  12. Remove spring, pawl pin and parking lock pawl. Remove underdrive clutch assembly. See Fig 13. Remove thrust bearing and bearing race. Using a screwdriver, remove No. 2 one-way clutch snap ring. Remove No. 2 one-way clutch from transaxle case. Note position of index marks on No. 2 one-way clutch for reassembly reference. See Figure. Note position of outer race retainer on No. 2 one-way clutch for reassembly reference. See Fig 15. Remove outer race retainer from No. 2 one-way clutch.
  13. Using a screwdriver, remove underdrive brake snap ring. Remove flange, 3 discs and 3 plates from transaxle case. Note location of components during removal for reassembly reference. Using appropriate press, compress underdrive brake piston return spring. Using snap ring expander, remove snap ring from underdrive brake. Remove piston return spring. See Fig 13.
  14. Remove 11 bolts and transaxle rear cover. If necessary, tap on circumference of rear cover with plastic hammer to remove cover. Remove 2 oil seal rings from rear cover. Using appropriate puller, remove needle roller bearing, if necessary. See Fig 12. Remove bolt, clamp and 2 brake apply pipes. Using a screwdriver, remove 2 apply gaskets from rear of transaxle case. See Fig 13.
  15. Remove direct clutch with thrust bearing from transaxle case. Remove bearing race from direct clutch (shaft side). Remove rear planetary sun gear assembly from transaxle case. Remove thrust bearing from rear planetary sun gear. Remove thrust washer No. 1 from rear planetary sun gear.
  16. Remove No. 1 one-way clutch and thrust bearing from transaxle case. Remove inner race from one-way clutch. Remove one-way clutch outer sleeve from transaxle case. Note direction of components for reassembly reference. Using a screwdriver, remove 2nd brake snap ring. Remove flange, 3 discs and 3 plates from transaxle case. Note location of components during removal for reassembly reference. See Fig 12.
  17. Using a screwdriver, remove rear planetary gear snap ring. Remove rear planetary gear from transaxle case. Remove thrust washer No. 2 from rear planetary gear. Remove 2 bearing races, thrust bearings and front planetary sun gear from transaxle case. See Fig 12.
  18. Using a hammer and chisel, unstake washer located on counter drive gear. See Fig 12. Ensure all claws on washer are pushed down to allow socket to fit securely on nut. Using holding tool and socket, remove nut. See Fig 16. Using appropriate adapter and press, remove front planetary gear from counter drive gear. See Fig 17.
  19. Using a screwdriver, remove 2nd brake assembly snap ring. Remove brake hub with 2nd brake assembly. Remove brake hub from 2nd brake assembly. See Fig 12. Using a screwdriver, remove snap ring and front planetary ring gear from brake hub. Remove 1st/reverse brake flange, 5 discs and 5 plates from transaxle case. Note location of components during removal for reassembly reference.
    20. NOTE: In the following step, stop press when piston return spring seat is lowered .039-.079" (1.00-2.00 mm) from snap ring groove. This prevents spring seat from becoming deformed. DO NOT expand snap ring excessively.
  20. Using appropriate press, compress 1st/reverse brake piston return spring. Using snap ring expander, remove snap ring from underdrive brake. Remove piston return spring. Using 57 psi (4 kg/cm2 ) of compressed air applied to transaxle case, remove 1st/reverse brake piston from case. See Fig 18. Cover piston with shop towel during removal.
  21. Using appropriate adapter and press, remove counter drive gear from transaxle case. Install and tighten 2 bolts opposite each other evenly on counter drive gear. Ensure clearance between counter drive gear and bearing race is about .79" (20.0 mm). Using bearing puller, remove rear tapered roller bearing from counter drive gear. See Fig 12.
  22. Using a brass drift and hammer, remove bearing inner and outer races. Remove snap ring at underdrive brake piston from transaxle case. Using 57 psi (4 kg/cm2 ) of compressed air applied to transaxle case, remove underdrive brake piston from case. See Fig 19. Cover piston with shop towel during removal.
  23. Using appropriate puller, remove needle roller bearing from transaxle case. Remove 2 oil seal rings from transaxle case. See Fig 21. Using appropriate puller, remove cylindrical roller bearing from transaxle case.
  24. Remove oil seal ring from transaxle housing. See Fig 20. Remove bolt, clamp and apply pipe from transaxle case. Remove 3 bolts and oil deflector (if equipped) from transaxle case. See Fig 2.
    Fig 12: Exploded View Of Transaxle Internal Components (1 Of 2)
    G00011249Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    Fig 13: Exploded View Of Transaxle Internal Components (2 Of 2)
    G00011250Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    Fig 14: Pushing Parking Lock Pawl Toward Case
    G00011251Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    Fig 15: Removing & Installing Outer Race Retainer
    G00011308Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    Fig 16: Removing & Installing Counter Drive Gear Nut
    G00011252Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    Fig 17: Removing Front Planetary Gear From Counter Drive Gear
    G00011253Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    Fig 18: Removing 1st/Reverse Brake Piston
    G00011254Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    Fig 19: Removing Underdrive Brake Piston
    G00011255Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    Fig 20: Removing & Installing Transaxle Housing Oil Seal Ring
    G00011309Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    Fig 21: Removing Underdrive Clutch Oil Seal Rings
    G00182276Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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