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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: Identifying Control Shaft Lever LH Nut & Washer
      G04963491Courtesy 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.
      Fig 2: Identifying Park/Neutral Position Switch Nut, Lock Washer & Bolt
      G04963492Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  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.
  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: Identifying Transmission Revolution Sensor Bolts
      G04963494Courtesy 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 breather tube.
      Fig 4: Identifying Breather Tube Bolts
      G04963495Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  6. REMOVE AUTOMATIC TRANSMISSION HOUSING 
    1. Remove the 10 bolts.
    2. Remove the transmission housing.
      Fig 5: Identifying Transmission Housing Bolts
      G04963496Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  7. REMOVE TRANSMISSION CASE ADAPTER SUB-ASSEMBLY 
    1. Remove the 8 bolts and transmission case adapter.
      Fig 6: Identifying Transmission Case Adapter Bolts
      G05110769Courtesy 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
      G05110770Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  9. FIX AUTOMATIC TRANSMISSION CASE SUB-ASSEMBLY 
    1. Install the transmission case onto the overhaul attachment.
      Fig 8: Identifying Transmission Case On Overhaul Attachment
      G04963501Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  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.
  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 from the valve body.
    3. Remove the O-ring form the valve body oil strainer assembly.
      Fig 9: Identifying Valve Body Oil Strainer Assembly Bolts
      G04963502Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  13. REMOVE TRANSMISSION WIRE 
    1. Remove the ATF temperature sensor.
    2. Remove the 2 bolts and 2 clamps.
    3. Disconnect the 7 connectors from the shift solenoid valves.
      Fig 10: Identifying Bolts & Clamps
      G04963503Courtesy 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: Identifying Case Bolt
      G04963504Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  14. REMOVE TRANSMISSION VALVE BODY ASSEMBLY 
    1. Remove the 19 bolts.
    2. Remove the valve body assembly.
      Fig 12: Identifying Valve Body Assembly Bolts
      G04963505Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  15. REMOVE TRANSAXLE CASE GASKET 
    1. Remove the 3 transaxle case gaskets.
      Fig 13: Identifying Transaxle Case Gaskets
      G05110776Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  16. REMOVE BRAKE DRUM GASKET 
    1. Remove the 3 brake drum gaskets.
      Fig 14: Identifying Brake Drum Gaskets
      G04963507Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  17. REMOVE CHECK BALL BODY 
    1. Remove the check ball body and the spring.
      Fig 15: Identifying Check Ball Body & Spring
      G04963508Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  18. REMOVE C-2 ACCUMULATOR PISTON 
    1. Applying compressed air to the oil hole, 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 pistons may jump out.
      Fig 16: Applying Compressed Air To Oil Hole To Remove C-2 Accumulator Piston & Spring
      G04963509Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  19. REMOVE B-3 ACCUMULATOR PISTON 
    1. Applying compressed air to the oil hole, 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: Applying Compressed Air To Oil Hole To Remove B-3 Accumulator Piston & Spring
      G04963509Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  20. REMOVE C-3 ACCUMULATOR PISTON 
    1. Applying compressed air to the oil hole, remove the C-3 accumulator piston and 2 springs.
    2. Remove the 2 O-rings from the piston.
      Fig 18: Applying Compressed Air To Oil Hole To Remove C-3 Accumulator Piston & Springs
      G04963511Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  21. REMOVE C-1 ACCUMULATOR VALVE 
    1. Remove the C-1 accumulator valve and 2 springs.
      Fig 19: Identifying C-1 Accumulator Valve & Springs
      G04963512Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  22. REMOVE PARKING LOCK PAWL BRACKET 
    1. Remove the 3 bolts and parking lock pawl bracket.
      Fig 20: Identifying Parking Lock Pawl Bracket Bolts
      G04963513Courtesy 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: Identifying Parking Lock Rod
      G04963514Courtesy 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: Identifying E-Ring
      G04965086Courtesy 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
      G04963516Courtesy 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
      G04963517Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  26. REMOVE MANUAL VALVE LEVER SHAFT OIL SEAL 
    1. Using a screwdriver, remove the 2 oil seals.
      Fig 25: Using Screwdriver To Remove Manual Valve Lever Shaft Oil Seals
      G04963518Courtesy 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: Identifying Oil Pump Assembly Bolts
      G04963519Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using SST, remove the oil pump.

      SST 09350-30020 (09350-07020) 

      Fig 27: Using SST To Remove Oil Pump
      G04963520Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Remove the No. 1 thrust bearing race from the front oil pump.
      Fig 28: Identifying No. 1 Thrust Bearing Race
      G04963521Courtesy 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: Identifying Clutch Drum & Input Shaft Drum Assembly
      G04963522Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the clutch drum thrust washer, No. 2 thrust bearing race and thrust needle roller bearing.
      Fig 30: Identifying Clutch Drum Thrust Washer, No. 2 Thrust Bearing Race & Thrust Needle Roller Bearing
      G05110323Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  29. INSPECT NO. 2 1-WAY CLUTCH ASSEMBLY  (See INSPECTION  )
  30. REMOVE NO. 2 1-WAY CLUTCH ASSEMBLY 
    1. Remove the No. 2 1-way clutch assembly and No. 2 clutch drum thrust washer from the clutch drum and input shaft assembly.
      Fig 31: Identifying No. 2 1-Way Clutch Assembly & No. 2 Clutch Drum Thrust Washer
      G04963524Courtesy 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: Using Screwdriver To Remove No. 3 Brake Snap Ring From Case
      G04963525Courtesy 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.
      Fig 33: Identifying Flange, Cushion Plate, Discs & Plates
      G04963526Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  33. INSPECT NO. 3 BRAKE DISC  (See INSPECTION  )
  34. REMOVE 2ND BRAKE PISTON HOLE SNAP RING 
    1. Using SST, remove the snap ring.

    SST 09350-30020 (09350-07060) 

    Fig 34: Using SST To Remove 2nd Brake Piston Hole Snap Ring
    G04963527Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  35. REMOVE 1-WAY CLUTCH ASSEMBLY 
    1. Remove the 1-way clutch assembly and No. 1 planetary carrier thrust washer from the case.
      Fig 35: Identifying 1-Way Clutch Assembly & No. 1 Planetary Carrier Thrust Washer
      G04963528Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  36. REMOVE 2ND BRAKE CYLINDER 
    1. Remove the 2nd brake cylinder from the case.
      Fig 36: Identifying 2nd Brake Cylinder
      G04963529Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  37. REMOVE 2ND BRAKE PISTON 
    1. Using SST and a press, remove the snap ring.

      SST 09351-40010 

    2. Remove the 2nd brake piston return spring from the 2nd brake piston.
      Fig 37: Using SST & Press To Remove Snap Ring
      G04963530Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. 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: Applying Compressed Air To 2nd Brake Cylinder
      G04963531Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Remove the 2 O-rings from the 2nd brake piston.
      Fig 39: Identifying 2nd Brake Piston O-Rings
      G04963532Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  38. INSPECT NO. 3 BRAKE PISTON RETURN SPRING SUB-ASSEMBLY  (See INSPECTION  )
  39. REMOVE FRONT PLANETARY GEAR ASSEMBLY 
    1. Remove the front planetary gear and 1-way clutch inner race from the case.
      Fig 40: Identifying Front Planetary Gear & 1-Way Clutch Inner Race
      G04963533Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the thrust needle roller bearing, No. 3 thrust bearing race and No. 2 planetary carrier thrust washer from the front planetary gear.
      Fig 41: Identifying Thrust Needle Roller Bearing, No. 3 Thrust Bearing Race & No. 2 Planetary Carrier Thrust Washer
      G04963534Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  40. INSPECT FRONT PLANETARY GEAR ASSEMBLY  (See INSPECTION  )
  41. INSPECT 1-WAY CLUTCH ASSEMBLY  (See INSPECTION  )
  42. REMOVE FRONT PLANETARY RING GEAR 
    1. Remove the front planetary ring gear from the transmission case.
      Fig 42: Identifying Front Planetary Ring Gear
      G05110235Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  43. REMOVE CENTER PLANETARY RING GEAR 
    1. Using a screwdriver, remove the snap ring.
      Fig 43: Using Screwdriver To Remove Center Planetary Snap Ring
      G04963536Courtesy 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 44: Identifying Center Planetary Ring Gear & Front Planetary Ring Gear Flange
      G04963537Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  44. REMOVE NO. 1 BRAKE DISC 
    1. Remove the flange, 3 discs and 3 plates from the case.
      Fig 45: Identifying Flange, Discs & Plates
      G04963538Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  45. INSPECT NO. 1 BRAKE DISC  (See INSPECTION  )
  46. REMOVE BRAKE PISTON RETURN SPRING SNAP RING 
    1. Using a screwdriver, remove the brake piston return spring snap ring from the case.
      Fig 46: Using Screwdriver To Remove Brake Piston Return Spring Snap Ring
      G04963539Courtesy 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.
      Fig 47: Identifying Brake Piston Return Spring & No. 1 Brake Piston With No. 1 Brake Cylinder
      G04963540Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  48. INSPECT BRAKE PISTON RETURN SPRING SUB-ASSEMBLY  (See INSPECTION  )
  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 48: Applying Compressed Air To Transmission Case
      G04963541Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  50. REMOVE NO. 2 BRAKE DISC 
    1. Using a screwdriver, remove the snap ring from the case.
      Fig 49: Using Screwdriver To Remove Snap Ring From Case
      G04963542Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the flange, brake piston return spring, 3 discs and 3 plates from the case.
      Fig 50: Identifying Flange, Brake Piston Return Spring, Discs & Plates
      G04963543Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  51. INSPECT NO. 2 BRAKE DISC  (See INSPECTION  )
  52. INSPECT NO. 2 BRAKE PISTON RETURN SPRING SUB-ASSEMBLY  (See INSPECTION  )
  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 51: Applying Compressed Air To Transmission Case
      G04963544Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  54. REMOVE CENTER PLANETARY GEAR ASSEMBLY 
    1. Remove the center planetary gear assembly, planetary sun gear, thrust needle roller bearing and No. 4 thrust bearing race from the case.
      Fig 52: Identifying Center Planetary Gear Assembly, Planetary Sun Gear, Thrust Needle Roller Bearing & No. 4 Thrust Bearing Face
      G05110245Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  55. INSPECT CENTER PLANETARY GEAR ASSEMBLY  (See INSPECTION  )
  56. REMOVE INTERMEDIATE SHAFT 
    1. Using a screwdriver, remove the snap ring from the case.
      Fig 53: Using Screwdriver To Remove Snap Ring
      G04963546Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the intermediate shaft with the No. 3 1-way clutch assembly from the case.
      Fig 54: Identifying Intermediate Shaft & No. 3 1-Way Clutch Assembly
      G04963547Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  57. INSPECT NO. 3 1-WAY CLUTCH ASSEMBLY  (See INSPECTION )
  58. REMOVE NO. 3 1-WAY CLUTCH ASSEMBLY 
    1. Remove the No. 3 1-way clutch assembly and 1-way clutch inner race from the intermediate shaft.
      Fig 55: Identifying No. 3 1-Way Clutch Assembly
      G04963548Courtesy 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 rear planetary ring gear flange from the intermediate shaft.
      Fig 56: Identifying No. 8 Thrust Bearing Race, Thrust Needle Roller Bearing, No. 7 Thrust Bearing Race & Planetary Ring Gear Flange
      G04963597Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  60. INSPECT REAR PLANETARY RING GEAR FLANGE SUB-ASSEMBLY  (See INSPECTION  )
  61. INSPECT INTERMEDIATE SHAFT  (See INSPECTION  )
  62. REMOVE BRAKE PLATE STOPPER SPRING 
    1. Remove the brake plate stopper spring from the case.
      Fig 57: Identifying Brake Plate Stopper Spring
      G04963550Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  63. REMOVE NO. 4 BRAKE DISC 
    1. Remove the 7 plates, 8 discs and 2 flanges from the case.
      Fig 58: Identifying Plates, Discs & Flanges
      G05191418Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  64. INSPECT NO. 4 BRAKE DISC  (See INSPECTION  )
  65. REMOVE REAR PLANETARY GEAR ASSEMBLY 
    1. Remove the rear planetary gear assembly from the case.
      Fig 59: Identifying Rear Planetary Gear Assembly
      G04963552Courtesy 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 60: Identifying Thrust Bearing Race & Thrust Needle Roller Bearing
      G04965161Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Remove the thrust needle roller bearing from the case.
      Fig 61: Identifying Thrust Needle Roller Bearing
      G04963554Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  66. INSPECT REAR PLANETARY GEAR ASSEMBLY  (See INSPECTION  )
  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) 

      Fig 62: Using SST To Remove Snap Ring & Reverse Brake Return Spring
      G04963555Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  68. INSPECT 1ST AND REVERSE BRAKE RETURN SPRING SUB-ASSEMBLY  (See INSPECTION  )
  69. REMOVE 1ST AND REVERSE BRAKE PISTON 
    1. Hold the 1st and reverse 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 1st and reverse brake piston.
      Fig 63: Applying Compressed Air To Transmission Case
      G04963556Courtesy 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 64: Using SST To Remove Brake Reaction Sleeve
      G04963557Courtesy 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 65: Using SST To Remove No. 4 Brake Piston
      G04965129Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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