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Automatic Transmission Unit: Disassembly

  1. REMOVE TRANSMISSION CONTROL SHAFT LEVER LH 
    1. Remove the nut, washer and control shaft lever LH.
      Fig 1: Removing Control Shaft Lever LH
      G04436662Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  2. REMOVE PARK/NEUTRAL POSITION SWITCH ASSEMBLY 
    1. Using a screwdriver, pry out the lock washer.
    2. Remove the nut, lock washer and bolt.
    3. Remove the park/neutral position switch.
  3. REMOVE OIL COOLER TUBE UNION 
    1. Remove the 2 oil cooler tube unions.
    2. Remove the O-ring from the oil cooler tube union.
      Fig 2: Removing Park/Neutral Position Switch Assembly
      G04436663Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  4. REMOVE TRANSMISSION REVOLUTION SENSOR 
    1. Remove the 2 bolts and 2 transmission revolution sensors.
    2. Remove the O-ring from each sensor.
      Fig 3: Removing Transmission Revolution Sensors
      G04436664Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  5. REMOVE AUTOMATIC TRANSAXLE BREATHER TUBE 
    1. Remove the 3 bolts.
    2. Remove the breather tube.
    3. Remove the O-ring from each tube.
      Fig 4: Removing Automatic Transaxle Breather Tube
      G04436665Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  6. REMOVE AUTOMATIC TRANSMISSION HOUSING 
    1. Remove the 10 bolts.
    2. Remove the transmission housing.
      Fig 5: Removing Automatic Transmission Housing
      G04436666Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  7. REMOVE TRANSMISSION CASE ADAPTER SUB-ASSEMBLY 
    1. Remove the 8 bolts.
    2. Remove the transmission case adapter assembly.

      HINT:

      Use a brass bar and a hammer to remove the extension housing assembly.

    3. Remove the gasket from the transmission case adapter assembly.
      Fig 6: Removing Transmission Case Adapter Assembly
      G04436667Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  8. REMOVE TRANSMISSION CASE ADAPTOR OIL SEAL 
    1. Using a screwdriver, pry out the oil seal.
      Fig 7: Prying Out Oil Seal Using Screwdriver
      G04436668Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  9. FIX AUTOMATIC TRANSMISSION CASE SUB-ASSEMBLY 
    1. Install the transmission case on the overhaul attachment.
  10. REMOVE AUTOMATIC TRANSMISSION OIL PAN SUB-ASSEMBLY 
    NOTE: Do not turn the transmission over as this will contaminate the valve body with foreign matter on the bottom of the pan.
    1. Remove the drain plug and the 20 bolts.
      Fig 8: Installing Transmission Case On Overhaul Attachment
      G04436669Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  11. INSPECT AUTOMATIC TRANSMISSION OIL PAN SUB-ASSEMBLY (See  INSPECTION   ) 
  12. REMOVE VALVE BODY OIL STRAINER ASSEMBLY 
    1. Turn over the transmission.
    2. Remove the 4 bolts holding the valve body oil strainer assembly to the valve body.
    3. Remove the O-ring from the valve body oil strainer assembly.
      Fig 9: Removing Valve Body Oil Strainer Assembly
      G04436670Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  13. REMOVE TRANSMISSION WIRE 
    1. Remove the ATF temperature sensor.
    2. Remove the bolt and clamp.
    3. Disconnect the 7 connectors from the shift solenoid valves.
      Fig 10: Removing Clamp
      G04436671Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Remove the bolt from the case.
    5. Pull the transmission wire out of the transmission case.
    6. Remove the O-ring from the transmission wire.
      Fig 11: Removing Transmission Wire
      G04436672Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  14. REMOVE TRANSMISSION VALVE BODY ASSEMBLY 
    1. Remove the 19 bolts.
    2. Remove the valve body assembly.
      Fig 12: Removing Transmission Valve Body Assembly
      G04436673Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  15. REMOVE TRANSAXLE CASE GASKET 
    1. Remove the 3 transaxle case gaskets.
      Fig 13: Removing Transaxle Case Gaskets
      G04436674Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  16. REMOVE BRAKE DRUM GASKET 
    1. Remove the 3 brake drum gaskets.
      Fig 14: Removing Brake Drum Gaskets
      G04436675Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  17. REMOVE CHECK BALL BODY 
    1. Remove the check ball body and spring.
      Fig 15: Removing Check Ball Body & Spring
      G04436676Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  18. REMOVE C-2 ACCUMULATOR PISTON 
    1. Applying compressed air to the oil hole, and remove the C-2 accumulator piston and spring.
    2. Remove the 2 O-rings from the piston.
      NOTE: Be careful as the C-3 and B-3 accumulator piston may jump out.
      Fig 16: Removing C-2 Accumulator Piston & Spring
      G04436677Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  19. REMOVE B-3 ACCUMULATOR PISTON 
    1. Applying compressed air to the oil hole, and remove the B-3 accumulator piston and spring.
    2. Remove the 2 O-rings from the piston.
      NOTE: Be careful as the C-3 accumulator piston may jump out.
      Fig 17: Removing B-3 Accumulator Piston & Spring
      G04436678Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  20. REMOVE C-3 ACCUMULATOR PISTON 
    1. Applying compressed air to the oil hole, and remove the C-3 accumulator piston and spring.
    2. Remove the 2 O-rings from the piston.
      Fig 18: Removing C-3 Accumulator Piston & Spring
      G04436679Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  21. REMOVE C-1 ACCUMULATOR VALVE 
    1. Remove the C-1 accumulator valve and 2 springs.
      Fig 19: Removing C-1 Accumulator Valve & Springs
      G04436680Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  22. REMOVE PARKING LOCK PAWL BRACKET 
    1. Remove the 3 bolts and parking lock pawl bracket.
      Fig 20: Removing Parking Lock Pawl Bracket & Bolts
      G04436681Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  23. REMOVE PARKING LOCK ROD SUB-ASSEMBLY 
    1. Disconnect the parking lock rod from the manual valve lever.
      Fig 21: Disconnecting Parking Lock Rod From Manual Valve Lever
      G04436682Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  24. REMOVE PARKING LOCK PAWL SHAFT 
    1. Pull out the parking lock pawl shaft from the front side, and then remove the lock pawl and spring.
    2. Remove the E-ring from the shaft.
      Fig 22: Pulling Out Parking Lock Pawl Shaft From Front Side
      G04436683Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  25. REMOVE MANUAL VALVE LEVER SUB-ASSEMBLY 
    1. Using a hammer and screwdriver, cut off the spacer and remove it from the shaft.
      Fig 23: Cutting Off Spacer Using Hammer & Screwdriver
      G04436684Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using a pin punch and hammer, tap out the spring pin.

      HINT:

      Slowly drive out the spring pin so that it does not fall into the transmission case.

    3. Pull the manual valve lever shaft out through the case, and remove the manual valve lever.
      Fig 24: Tapping Out Spring Pin Using Pin Punch & Hammer
      G04436685Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  26. REMOVE MANUAL VALVE LEVER SHAFT OIL SEAL 
    1. Using a screwdriver, pry out the 2 oil seals.
      Fig 25: Prying Out Oil Seals Using Screwdriver
      G04436686Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  27. REMOVE OIL PUMP ASSEMBLY 
    1. Remove the 10 bolts holding the oil pump from the transmission case.
      Fig 26: Removing Oil Pump Bolts
      G04436687Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using SST, remove the oil pump.

      SST 09350-30020 (09350-07020) 

      Fig 27: Removing Oil Pump Using SST
      G04436688Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Remove the No. 1 thrust bearing race from the front oil pump.
      Fig 28: Removing No. 1 Thrust Bearing Race From Front Oil Pump
      G04436689Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  28. REMOVE CLUTCH DRUM AND INPUT SHAFT ASSEMBLY 
    1. Remove the clutch drum and input shaft drum assembly from the transmission case.
      Fig 29: Removing Clutch Drum & Input Shaft Drum Assembly From Transmission Case
      G04436690Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the clutch drum thrust washer and thrust needle roller bearing.
  29. INSPECT NO. 2 ONE-WAY CLUTCH ASSEMBLY (See  INSPECTION   ) 
    Fig 30: Removing Clutch Drum Thrust Washer & Thrust Needle Roller Bearing
    G04436691Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  30. REMOVE NO. 2 ONE-WAY CLUTCH ASSEMBLY 
    1. Remove the No. 2 one-way clutch assembly and No. 2 clutch drum thrust washer from the clutch drum and input shaft assembly.
      Fig 31: Removing No. 2 One-Way Clutch Assembly & No. 2 Clutch Drum Thrust Washer
      G04436692Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  31. REMOVE NO. 3 BRAKE SNAP RING 
    1. Using a screwdriver, remove the No. 3 brake snap ring from the case.
      Fig 32: Removing No. 3 Brake Snap Ring From Case Using Screwdriver
      G04436693Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  32. REMOVE NO. 3 BRAKE DISC 
    1. Remove the flange, cushion plate, 4 discs and 4 plates from the case.
  33. INSPECT NO. 3 BRAKE DISC (See  INSPECTION   ) 
    Fig 33: Removing Flange, Cushion Plate, Discs & Plates From Case
    G04436694Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  34. REMOVE 2ND BRAKE PISTON HOLE SNAP RING 
    1. Using SST, remove the snap ring.

      SST 09350-30020 (09350-07060) 

      Fig 34: Removing Snap Ring Using SST
      G04436695Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  35. REMOVE ONE-WAY CLUTCH ASSEMBLY 
    1. Remove the one-way clutch assembly and No. 1 planetary carrier thrust washer from the case.
      Fig 35: Removing One-Way Clutch Assembly
      G04436696Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  36. REMOVE 2ND BRAKE CYLINDER 
    1. Remove the 2nd brake cylinder from the case.
      Fig 36: Removing 2nd Brake Cylinder From Case
      G04436697Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  37. REMOVE 2ND BRAKE PISTON 
    1. Using SST, a press and screwdriver, remove the snap ring.

      SST 09351-40010 

      Fig 37: Removing Snap Ring Using SST, Press & Screwdriver
      G04436698Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Hold the 2nd brake piston and apply compressed air (392 kPa, 4.0 kgf/cm2 , 57 psi) to the brake cylinder to remove the 2nd brake piston.
      Fig 38: Removing 2nd Brake Piston
      G04436699Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Remove the 2 O-rings from the 2nd brake piston.
  38. INSPECT NO. 3 BRAKE PISTON RETURN SPRING SUB-ASSEMBLY (See  INSPECTION   ) 
  39. REMOVE FRONT PLANETARY GEAR ASSEMBLY 
  40. INSPECT FRONT PLANETARY GEAR ASSEMBLY (See  INSPECTION   ) 
  41. INSPECT ONE-WAY CLUTCH ASSEMBLY (See  INSPECTION   ) 
    Fig 39: Removing O-Rings From 2nd Brake Piston
    G04436700Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  42. REMOVE FRONT PLANETARY RING GEAR 
    1. Remove the front planetary ring gear and bearing from the transmission case.
      Fig 40: Removing Front Planetary Ring Gear & Bearing From Transmission Case
      G04436701Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  43. REMOVE CENTER PLANETARY RING GEAR 
    1. Using a screwdriver, remove the snap ring.
      Fig 41: Removing Snap Ring Using Screwdriver
      G04436702Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the center planetary ring gear and front planetary ring gear flange from the front planetary ring gear.
      Fig 42: Removing Center Planetary Ring Gear & Front Planetary Ring Gear Flange From Front Planetary Ring Gear
      G04436703Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  44. REMOVE NO. 1 BRAKE DISC 
    1. Remove the flange, 3 discs and 3 plates from the case.
  45. INSPECT NO. 1 BRAKE DISC (See  INSPECTION   ) 
    Fig 43: Removing Flange, Discs & Plates From Case
    G04436704Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  46. REMOVE BRAKE PISTON RETURN SPRING SNAP RING 
    1. Using a screwdriver, remove the brake piston return spring snap ring from the case.
      Fig 44: Removing Brake Piston Return Spring Snap Ring From Case Using Screwdriver
      G04436705Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  47. REMOVE BRAKE PISTON RETURN SPRING SUB-ASSEMBLY 
    1. Remove the brake piston return spring and No. 1 brake piston with the No. 1 brake cylinder from the transmission case.
  48. INSPECT BRAKE PISTON RETURN SPRING SUB-ASSEMBLY (See  INSPECTION   ) 
    Fig 45: Removing Brake Piston Return Spring Sub-Assembly
    G04436706Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  49. REMOVE NO. 1 BRAKE PISTON 
    1. Hold the No. 1 brake piston and apply compressed air (392 kPa, 4 kgf/cm2 , 57 psi) to the transmission case to remove the No. 1 brake piston.

      HINT:

      If the piston does not pop out with compressed air, lift the piston out with needle-nose pliers.

    2. Remove the 2 O-rings from the No. 1 brake piston.
      Fig 46: Removing No. 1 Brake Piston
      G04436707Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  50. REMOVE NO. 2 BRAKE DISC 
    1. Using a screwdriver, remove the snap ring from the case.
      Fig 47: Removing Snap Ring From Case Using Screwdriver
      G04436708Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the flange, brake piston return spring, 3 discs and 3 plates from the case.
  51. INSPECT NO. 2 BRAKE DISC (See  INSPECTION   ) 
  52. INSPECT NO. 2 BRAKE PISTON RETURN SPRING SUB-ASSEMBLY (See  INSPECTION   ) 
    Fig 48: Removing Flange, Brake Piston Return Spring, Discs & Plates From Case
    G04436709Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  53. REMOVE NO. 2 BRAKE PISTON 
    1. Hold the No. 2 brake piston and apply compressed air (392 kPa, 4 kgf/cm2 , 57 psi) to the transmission case to remove the No. 2 brake piston.

      HINT:

      If the piston does not pop out with compressed air, lift the piston out with needle-nose pliers.

    2. Remove the 2 O-rings from the No. 2 brake piston.
      Fig 49: Removing No. 2 Brake Piston
      G04436710Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  54. REMOVE CENTER PLANETARY GEAR ASSEMBLY 
    1. Remove the center planetary gear assembly, planetary sun gear and No. 4 thrust bearing race from the case.
  55. INSPECT CENTER PLANETARY GEAR ASSEMBLY (See  INSPECTION   ) 
    Fig 50: Removing Center Planetary Gear Assembly
    G04436711Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  56. REMOVE INTERMEDIATE SHAFT 
    1. Using a screwdriver, remove the snap ring from the case.
      Fig 51: Removing Snap Ring From Case
      G04436712Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the intermediate shaft with the No. 3 one-way clutch assembly from the case.
  57. INSPECT NO. 3 ONE-WAY CLUTCH ASSEMBLY (See  INSPECTION   ) 
    Fig 52: Removing Intermediate Shaft
    G04436713Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  58. REMOVE NO. 3 ONE-WAY CLUTCH ASSEMBLY 
    1. Remove the No. 3 one-way clutch assembly and one-way clutch inner race from the intermediate shaft.
      Fig 53: Removing No. 3 One-Way Clutch Assembly & One-Way Clutch Inner Race From Intermediate Shaft
      G04436714Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  59. REMOVE REAR PLANETARY RING GEAR FLANGE SUB-ASSEMBLY 
    1. Remove the No. 8 thrust bearing race, thrust needle roller bearing, No. 7 thrust bearing race and planetary ring gear flange from the intermediate shaft.
  60. INSPECT REAR PLANETARY RING GEAR FLANGE SUB-ASSEMBLY (See  INSPECTION   ) 
  61. INSPECT INTERMEDIATE SHAFT (See  INSPECTION   ) 
    Fig 54: Removing No. 8 Thrust Bearing Race & Thrust Needle Roller Bearing
    G04436715Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  62. REMOVE BRAKE PLATE STOPPER SPRING 
    1. Remove the brake plate stopper spring from the case.
      Fig 55: Removing Brake Plate Stopper Spring From Case
      G04436716Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  63. REMOVE NO. 4 BRAKE DISC 
    1. Remove the 7 plates, 8 discs and 2 flanges from the case.
  64. INSPECT NO. 4 BRAKE DISC (See  INSPECTION   ) 
    Fig 56: Removing Plates, Discs & Flanges From Case
    G04436717Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  65. REMOVE REAR PLANETARY GEAR ASSEMBLY 
    1. Remove the rear planetary gear assembly from the case.
      Fig 57: Removing Rear Planetary Gear Assembly From Case
      G04436718Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the No. 9 thrust bearing race and thrust needle roller bearing from the rear planetary gear assembly.
      Fig 58: Removing No. 9 Thrust Bearing Race & Thrust Needle Roller Bearing From Rear Planetary Gear Assembly
      G04436719Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Remove the thrust needle roller bearing from the case.
  66. INSPECT REAR PLANETARY GEAR ASSEMBLY (See  INSPECTION   ) 
    Fig 59: Removing Thrust Needle Roller Bearing From Case
    G04436720Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  67. REMOVE 1ST AND REVERSE BRAKE RETURN SPRING SUB-ASSEMBLY 
    1. Place SST on the spring retainer and compress the brake return spring.

      SST 09350-30020 (09350-07050) 

    2. Using SST, remove the snap ring and brake return spring.

      SST 09350-30020 (09350-07070) 

  68. INSPECT 1ST AND REVERSE BRAKE RETURN SPRING SUB-ASSEMBLY (See  INSPECTION   ) 
    Fig 60: Removing Snap Ring & Brake Return Spring
    G04436721Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  69. REMOVE 1ST AND REVERSE BRAKE PISTON 
    1. Hold the No. 2 brake piston and apply compressed air (392 kPa, 4 kgf/cm2 , 57 psi) to the transmission case to remove the No. 2 brake piston.

      HINT:

      If the piston does not pop out with compressed air, lift the piston out with needle-nose pliers.

    2. Remove the O-ring from the No. 2 brake piston.
      Fig 61: Removing 1st & Reverse Brake Piston
      G04436722Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  70. REMOVE BRAKE REACTION SLEEVE 
    1. Using SST, remove the reaction sleeve.

      SST 09350-30020 (09350-07080) 

    2. Remove the O-ring from the reaction sleeve.
      Fig 62: Removing Brake Reaction Sleeve Using SST
      G04436723Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  71. REMOVE NO. 4 BRAKE PISTON 
    1. Using SST, remove the No. 4 brake piston.

      SST 09350-30020 (09350-07090) 

    2. Remove the 2 O-rings from the No. 4 piston.
      Fig 63: Removing No. 4 Brake Piston
      G04436724Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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