LEMON Manuals: Even more car manuals for everyone
Home >> Toyota >> 2009 >> Matrix Base, Standard >> Repair and Diagnosis >> External Pages >> Different variant/trim >> Section 13 (Automatic Transmission - U250E) >> Automatic Transaxle Unit >> Disassembly

Automatic Transaxle Unit: Disassembly

WARNING: This page is about a different variant/trim than selected.
  1. REMOVE PARK/NEUTRAL POSITION SWITCH ASSEMBLY 
    1. Remove the nut, washer and control shaft lever.
      Fig 1: Locating Control Shaft Lever Nut And Washer
      G06011613Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using a screwdriver, unstake the lock plate, and remove the lock nut and nut stopper.
      Fig 2: Unstaking Lock Plate
      G04975926Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Remove the 2 bolts and pull out the park/neutral position switch.
      Fig 3: Locating Park/Neutral Position Switch Bolts
      G04975931Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  2. REMOVE NO. 2 BREATHER PLUG 
    1. Remove the No. 2 breather plug from the transaxle case.
      Fig 4: Locating No. 2 Breather Plug
      G04976088Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the hose and O-ring from the No. 2 breather plug.
      Fig 5: Identifying O-Ring And No. 2 Breather Plug
      G04976089Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  3. REMOVE OIL COOLER TUBE ELBOW (INLET OIL COOLER ELBOW) 
    1. Remove the elbow.
    2. Remove the O-ring from the elbow.
      Fig 6: Identifying O-Ring And Elbow
      G06011936Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  4. REMOVE OIL COOLER TUBE UNION (OUTLET OIL COOLER UNION) 
    1. Remove the union.
    2. Remove the O-ring from the union.
      Fig 7: Identifying O-Ring And Union
      G06011619Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  5. REMOVE TRANSMISSION REVOLUTION SENSOR 
    1. Remove the 2 bolts and 2 speed sensors from the transaxle assembly.
    2. Remove the 2 O-rings from the 2 speed sensors.
      Fig 8: Identifying Speed Sensors With Bolts
      G06011620Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  6. REMOVE NO. 1 TRANSAXLE CASE PLUG 
    1. Remove the 4 No. 1 transaxle case plugs from the transaxle case.
    2. Remove the O-ring from each No. 1 transaxle case plug.
      Fig 9: Identifying O-Ring And No. 1 Transaxle Case Plug
      G06011621Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  7. SECURE AUTOMATIC TRANSAXLE ASSEMBLY 
    1. Secure the transaxle assembly onto wooden blocks.
      Fig 10: Identifying Transaxle Assembly Onto Wooden Blocks
      G04976094Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  8. REMOVE AUTOMATIC TRANSAXLE OIL PAN SUB-ASSEMBLY 
    1. Remove the drain plug and drain plug gasket from the oil pan.
    2. Remove the 18 bolts, oil pan and gasket.
      Fig 11: Locating Oil Pan Bolts
      G04975941Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Remove the 2 transmission oil cleaner magnets from the oil pan.
      Fig 12: Identifying Transmission Oil Cleaner Magnets
      G04976096Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  9. INSPECT TRANSMISSION OIL CLEANER MAGNET  (See INSPECTION )
  10. DISCONNECT TRANSMISSION WIRE 
    1. Disconnect the 7 connectors from the shift solenoid valves.
    2. Remove the bolt, lock plate, and ATF temperature sensor.
      Fig 13: Locating ATF Temperature Sensor And Connectors
      G06011626Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  11. REMOVE TRANSMISSION WIRE 
    1. Remove the bolt and transmission wire from the transaxle case.
      Fig 14: Identifying Transmission Wire Connector
      G04976099Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  12. REMOVE VALVE BODY OIL STRAINER ASSEMBLY 
    1. Remove the 3 bolts and oil strainer.
      Fig 15: Locating Oil Strainer Bolts
      G04976100Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the O-ring from the oil strainer.
      Fig 16: Locating Oil Strainer O-Ring
      G04976101Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  13. REMOVE TRANSMISSION VALVE BODY ASSEMBLY 
    1. Support the valve body assembly and remove the 17 bolts and valve body assembly.
      Fig 17: Locating Valve Body With Bolts
      G04975959Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  14. REMOVE NO. 1 GOVERNOR APPLY GASKET 
    1. Remove the No. 1 governor apply gasket from the transaxle case.
      Fig 18: Locating No. 1 Governor Apply Gasket
      G04976103Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  15. REMOVE TRANSAXLE CASE 2ND BRAKE GASKET 
    1. Remove the transaxle case 2nd brake gasket from the transaxle case.
      Fig 19: Locating Transaxle Case 2nd Brake Gasket
      G04976104Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  16. REMOVE BRAKE DRUM GASKET 
    1. Remove the brake drum gasket from the transaxle case.
      Fig 20: Locating Brake Drum Gasket
      G04976105Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  17. REMOVE CHECK BALL BODY 
    1. Remove the check ball body and spring from the transaxle case.
      Fig 21: Identifying Check Ball Body And Spring
      G04976106Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  18. REMOVE C-3 ACCUMULATOR PISTON 
    1. Remove the spring from the C-3 accumulator piston.
      Fig 22: Identifying C-3 Accumulator Piston Spring
      G04976107Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using needle-nose pliers, remove the C-3 accumulator piston from the transaxle case.
      Fig 23: Removing C-3 Accumulator Piston From Transaxle Case
      G06011636Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Remove the O-ring from the C-3 accumulator piston.
      Fig 24: Locating O-Ring
      G06011918Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  19. REMOVE REVERSE CLUTCH ACCUMULATOR PISTON 
    1. Apply compressed air (392 kPa, 4.0 kgf/cm2 , 57 psi) to the oil hole and remove the reverse accumulator piston and spring.
      NOTE:
      • Applying compressed air may cause the piston to jump out. When removing the piston, hold it by hand using a piece of cloth.
      • Do not splash ATF when applying compressed air.
        Fig 25: Applying Compressed Air To Oil Hole
        G06011638Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the 2 O-rings from the reverse clutch accumulator piston.
      Fig 26: Locating Reverse Clutch Accumulator Piston O-Ring
      G04976111Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  20. REMOVE B-3 ACCUMULATOR PISTON 
    1. Apply compressed air (392 kPa, 4.0 kgf/cm2 , 57 psi) to the oil hole and remove the B-3 accumulator piston and 2 springs.
      NOTE:
      • Applying compressed air may cause the piston to jump out. When removing the piston, hold it by hand using a piece of cloth.
      • Do not splash ATF when applying compressed air.
        Fig 27: Applying Compressed Air To Oil Hole
        G04976112Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the O-ring from the B-3 accumulator piston.
      Fig 28: Locating O-Ring
      G06044003Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  21. REMOVE MANUAL VALVE LEVER SHAFT RETAINER SPRING 
    1. Using needle-nose pliers, remove the manual valve lever shaft retainer spring.
      Fig 29: Removing/Installing Manual Valve Lever Shaft Retainer Spring
      G04976114Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  22. REMOVE MANUAL DETENT SPRING SUB-ASSEMBLY 
    1. Remove the 2 bolts and manual detent spring sub-assembly.
      Fig 30: Locating Manual Detent Spring Sub-Assembly Bolts
      G05000754Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  23. REMOVE PARKING LOCK PAWL BRACKET 
    1. Remove the 2 bolts and parking lock pawl bracket.
      Fig 31: Locating Parking Lock Pawl Bracket Bolts
      G04976116Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  24. REMOVE MANUAL VALVE LEVER SUB-ASSEMBLY 
    1. Using a screwdriver, slide the spacer as shown in the illustration.
      Fig 32: Sliding Spacer
      G04976117Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using a pin punch ( 3 mm) and a hammer, drive out the pin.

      HINT:

      Slowly drive out the pin so that it will not fall into the transaxle case.

      Fig 33: Tapping Transaxle Case Pin
      G04976118Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Remove the manual valve lever shaft, manual valve lever and spacer.
      Fig 34: Removing Manual Valve Lever Shaft
      G04976119Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  25. REMOVE PARKING LOCK ROD SUB-ASSEMBLY 
    1. Remove the parking lock rod sub-assembly from the manual valve lever sub-assembly.

      HINT:

      Align the dial with the notches on the manual valve lever sub-assembly to remove the parking lock rod sub-assembly.

      Fig 35: Identifying Parking Lock Rod Sub-Assembly
      G06011648Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  26. REMOVE MANUAL VALVE LEVER SHAFT OIL SEAL 
    1. Using a screwdriver, remove the oil seal from the transaxle case.
      Fig 36: Removing Oil Seal From Transaxle Case
      G04976121Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  27. SECURE AUTOMATIC TRANSAXLE ASSEMBLY 
    1. Secure the transaxle case with the oil pump facing up.
  28. INSPECT INPUT SHAFT END PLAY  (See INSPECTION )
  29. REMOVE TRANSAXLE HOUSING 
    1. Remove the 18 bolts.
      Fig 37: Locating Transaxle Housing Bolts
      G06011650Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Tap on the circumference of the transaxle housing with a plastic hammer to remove the transaxle housing from the transaxle case.
      NOTE: The differential may be accidentally removed when the transaxle housing is removed.
  30. REMOVE OIL PUMP ASSEMBLY 
    1. Remove the 7 bolts and oil pump from the transaxle case.
      Fig 38: Locating Oil Pump Bolts
      G04976123Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  31. REMOVE THRUST NEEDLE ROLLER BEARING 
    1. Remove the thrust needle roller bearing from the underdrive planetary gear assembly.
      Fig 39: Identifying Thrust Needle Roller Bearing And Differential Gear Assembly
      G06011652Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  32. REMOVE NO. 2 THRUST BEARING UNDERDRIVE RACE 
    1. Remove the No. 2 thrust bearing underdrive race from the underdrive planetary gear assembly.
      Fig 40: Identifying No. 2 Thrust Bearing Underdrive Race And Underdrive Planetary Gear Assembly
      G06011653Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  33. REMOVE DIFFERENTIAL GEAR ASSEMBLY 
    1. Remove the differential gear assembly from the transaxle case.
      Fig 41: Identifying Differential Gear Assembly
      G06011654Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  34. REMOVE OVERDRIVE BRAKE GASKET 
    1. Remove the 2 overdrive brake gaskets from the transaxle case.
      Fig 42: Identifying Overdrive Brake Gaskets
      G04976127Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  35. REMOVE FORWARD CLUTCH ASSEMBLY 
    1. Remove the forward clutch assembly from the transaxle case.
      Fig 43: Identifying Forward Clutch Assembly
      G06011656Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the thrust needle roller bearing from the forward clutch assembly.
      Fig 44: Identifying Thrust Needle Roller Bearing
      G04976129Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  36. INSPECT PACK CLEARANCE OF FORWARD CLUTCH  (See INSPECTION )
  37. REMOVE FORWARD MULTIPLE DISC CLUTCH DISC 
    1. Using a screwdriver, remove the snap ring.
      Fig 45: Removing/Installing Snap Ring
      G04976375Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the flange, 5 discs and 5 plates from the input shaft.
      Fig 46: Identifying Flange, Discs And Plates With Input Shaft
      G04976376Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  38. REMOVE FORWARD CLUTCH RETURN SPRING SUB-ASSEMBLY 
    1. Place SST on the spring retainer and compress the return spring with a press.

      SST 09387-00020 

      Fig 47: Compressing Return Spring With Press
      G04976377Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using a snap ring expander, remove the snap ring.
      NOTE:
      • Stop the press when the spring seat is lowered 1 to 2 mm (0.0393 to 0.0787 in.) from the snap ring groove. This prevents the spring seat from being deformed.
      • Do not expand the snap ring excessively.
    3. Remove the clutch balancer from the input shaft.
      Fig 48: Identifying Clutch Balancer And Input Shaft
      G04976378Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Remove the forward clutch return spring from the input shaft.
      Fig 49: Identifying Forward Clutch Return Spring And Input Shaft
      G04976379Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  39. REMOVE FORWARD CLUTCH PISTON SUB-ASSEMBLY 
    1. Place the input shaft drum onto the oil pump.
    2. Holding the forward clutch piston by hand, apply compressed air (392 kPa, 4.0 kgf/cm2 , 57 psi) to the oil pump to remove the forward clutch piston.

      HINT:

      If the piston is slanted and cannot be removed, either blow air again with the protruding side pushed, or remove the piston using needle nose pliers with the tips taped.

      Fig 50: Applying Compressed Air To Oil Pump
      G04976380Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  40. REMOVE INPUT SHAFT OIL SEAL RING 
    1. Remove the input shaft oil seal ring from the input shaft.
      Fig 51: Removing Input Shaft Oil Seal Ring
      G04976381Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  41. REMOVE MULTIPLE DISC CLUTCH HUB 
    1. Remove the thrust needle roller bearing, multiple disc clutch hub, thrust needle roller bearing and No. 1 thrust bearing race from the transaxle case.
      Fig 52: Identifying Thrust Needle Roller Bearing, Multiple Disc Clutch Hub And Thrust Needle Roller Bearing
      G06011665Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  42. INSPECT MULTIPLE DISC CLUTCH HUB  (See INSPECTION )
  43. REMOVE UNDERDRIVE PLANETARY GEAR ASSEMBLY 
    1. Remove the bolt and pawl shaft clamp from the transaxle case.
      Fig 53: Identifying Pawl Shaft Clamp
      G06011666Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the parking lock pawl shaft from the transaxle case.
      Fig 54: Removing Parking Lock Pawl Shaft
      G05000771Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Push the parking lock pawl.

      HINT:

      Failure to do so will cause interference when the underdrive planetary gear is removed.

      Fig 55: Pushing Parking Lock Pawl
      G04976133Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Remove the underdrive planetary gear assembly from the transaxle case.
      NOTE: Do not drop the underdrive planetary gear assembly.
      Fig 56: Identifying Underdrive Planetary Gear Assembly
      G06011669Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  44. REMOVE FRONT PLANETARY GEAR NUT 
    1. Using SST and a hammer, loosen the staked part of the gear nut.

      SST 09387-00050, 09495-65040, 09930-00010 (09931-00010, 09931-00020) 

      Fig 57: Removing Front Planetary Gear Nut
      G04976395Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Clamp the underdrive planetary gear in a soft jaw vise.
      NOTE: Be careful not to damage the differential drive pinion.
      Fig 58: Clamping Underdrive Planetary Gear In Soft Jaw Vise
      G04976396Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Using a socket wrench, remove the gear nut.
      Fig 59: Removing/Installing Underdrive Planetary Gear Nut
      G04976397Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  45. REMOVE CYLINDRICAL ROLLER BEARING RACE INNER 
    1. Using SST, remove the cylindrical roller bearing race inner.

      SST 09950-00020, 09950-00030, 09950-40011 (09957-04010), 09950-60010 (09951-00320) 

      Fig 60: Removing Cylindrical Roller Bearing Race Inner
      G05001042Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  46. REMOVE UNDERDRIVE PLANETARY GEAR ASSEMBLY 
    1. Using SST and a press, remove the differential drive pinion, parking lock gear, counter driven gear with underdrive planetary ring gear, and angular ball bearing.

      SST 09387-00050, 09495-65040, 09950-60010 (09951-00320), 09950-70010 (09951-07100) 

      Fig 61: Removing Underdrive Planetary Gear Assembly
      G04976399Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Clamp the underdrive planetary gear in a soft jaw vise.
    3. Using SST, remove the rear angular ball bearing from the underdrive planetary gear.

      SST 09950-00020, 09950-00030, 09950-40011 (09957-04010), 09950-60010 (09951-00320) 

      Fig 62: Removing Rear Angular Ball Bearing From Underdrive Planetary Gear
      G05559571Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  47. REMOVE UNDERDRIVE PLANETARY RING GEAR 
    1. Using snap ring pliers, remove the snap ring.
      Fig 63: Removing/Installing Underdrive Planetary Ring Gear Snap Ring
      G04976401Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the underdrive planetary ring gear from the counter driven gear.
      Fig 64: Identifying Underdrive Planetary Ring Gear And Counter Driven Gear
      G04976402Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  48. REMOVE PARKING LOCK PAWL 
    1. Remove the spring, pawl pin and parking lock pawl.
      Fig 65: Identifying Spring, Pawl Pin And Parking Lock Pawl
      G05000774Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  49. REMOVE UNDERDRIVE CLUTCH ASSEMBLY 
    1. Remove the underdrive clutch assembly, thrust bearing, and bearing race from the transaxle case.
      Fig 66: Identifying Thrust Bearing And Bearing Race
      G05559307Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  50. REMOVE NO. 2 UNDERDRIVE CLUTCH FLANGE HOLE SNAP RING 
    1. Using a screwdriver, remove the No. 2 underdrive clutch flange hole snap ring.
      Fig 67: Removing No. 2 Underdrive Clutch Flange Hole Snap Ring
      G04976419Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  51. REMOVE NO. 1 UNDERDRIVE CLUTCH DISC 
    1. Remove the flange, 3 discs, and 3 plates from the underdrive clutch drum.
      Fig 68: Identifying Underdrive Clutch Drum
      G04976420Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  52. REMOVE UNDERDRIVE CLUTCH RETURN SPRING SUB-ASSEMBLY 
    1. Place SST on the clutch balancer and compress the spring with a press.

      SST 09350-32014 (09351-32070) 

      Fig 69: Compressing Spring With Press
      G04976421Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using a snap ring expander, remove the snap ring.
      NOTE:
      • Stop the press when the spring seat is lowered 1 to 2 mm (0.0393 to 0.0787 in.) from the snap ring groove. This prevents the spring seat from being deformed.
      • Do not expand the snap ring excessively.
    3. Remove the clutch balancer from the underdrive clutch drum.
      Fig 70: Identifying Clutch Balancer And Underdrive Clutch Drum
      G04976422Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Remove the return spring from the underdrive clutch drum.
      Fig 71: Identifying Return Spring And Underdrive Clutch Drum
      G06044046Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  53. REMOVE UNDERDRIVE CLUTCH PISTON SET 
    1. Install the underdrive clutch into the transaxle case.
      NOTE: Be careful not to damage the oil seal ring.
    2. Holding the underdrive clutch piston by hand, apply compressed air (392 kPa, 4.0 kgf/cm2 , 57 psi) to the transaxle case to remove the underdrive clutch piston.
      Fig 72: Holding Underdrive Clutch Piston By Hand
      G05001068Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  54. REMOVE UNDERDRIVE CLUTCH DRUM O-RING 
    1. Using a screwdriver, remove the O-ring from the underdrive clutch drum.
      Fig 73: Locating Underdrive Clutch Drum O-Ring
      G04976430Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  55. REMOVE UNDERDRIVE ONE-WAY CLUTCH ASSEMBLY 
    1. Using a screwdriver, remove the snap ring from the transaxle case.
      Fig 74: Removing Snap Ring From Transaxle Case
      G04976137Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the underdrive one-way clutch from the transaxle case.
      Fig 75: Identifying Underdrive One-Way Clutch Assembly
      G06011688Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Remove the outer race retainer from the one-way clutch.
      Fig 76: Identifying Outer Race Retainer
      G04976139Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  56. REMOVE NO. 2 UNDERDRIVE CLUTCH DISC 
    1. Using a screwdriver, remove the snap ring.
      Fig 77: Removing/Installing No. 2 Underdrive Clutch Disc Snap Ring
      G04976140Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the flange, 3 discs and 3 plates from the transaxle case.
      Fig 78: Identifying Flange, Discs And Plates
      G04976141Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  57. INSPECT NO. 2 UNDERDRIVE CLUTCH DISC  (See INSPECTION )
  58. REMOVE TRANSAXLE REAR COVER SUB-ASSEMBLY 
    1. Remove the 11 bolts.
      Fig 79: Locating Transaxle Rear Cover Bolts
      G06011692Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Tap on the circumference of the rear cover with a plastic hammer to remove the transaxle rear cover from the transaxle case.
  59. REMOVE NO. 1 TRANSAXLE CASE PLUG 
    1. Remove the 4 No. 1 transaxle case plugs from the transaxle rear cover.
    2. Remove the O-ring from each No. 1 transaxle case plug.
      Fig 80: Identifying No. 1 Transaxle Case Plugs
      G06011693Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  60. REMOVE REAR CLUTCH OIL SEAL RING 
    1. Remove the 3 rear clutch oil seal rings from the transaxle rear cover.
      Fig 81: Identifying Rear Clutch Oil Seal Rings
      G06011694Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  61. REMOVE NEEDLE ROLLER BEARING 
    1. Using SST, remove the needle roller bearing from the transaxle rear cover.

      SST 09387-00041 (09387-01021, 09387-01030, 09387-01040) 

      Fig 82: Removing Needle Roller Bearing
      G04976145Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  62. REMOVE NO. 1 GOVERNOR APPLY GASKET 
    1. Using a screwdriver, remove the 3 apply gaskets.
      Fig 83: Locating No. 1 Governor Apply Gaskets
      G04976282Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  63. REMOVE BRAKE APPLY TUBE 
    1. Remove the bolt, clamp and brake apply tube.
    2. Remove the clutch apply tube.
    3. Remove the brake apply tube from the clamp.
      Fig 84: Locating Bolt, Clamp And Brake Apply Tube
      G06011697Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  64. REMOVE DIRECT CLUTCH ASSEMBLY 
    1. Remove the thrust bearing and the direct clutch assembly from the transaxle case.
      Fig 85: Identifying Thrust Bearing And Direct Clutch Assembly
      G06011698Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  65. INSPECT PACK CLEARANCE OF DIRECT CLUTCH  (See INSPECTION )
  66. INSPECT PACK CLEARANCE OF OVERDRIVE CLUTCH  (See INSPECTION )
  67. REMOVE DIRECT MULTIPLE DISC CLUTCH DISC 
    1. Using a screwdriver, remove the snap ring from the intermediate shaft.
      Fig 86: Removing Snap Ring From Intermediate Shaft
      G06011699Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the flange, 3 discs, 3 plates and cushion plate from the intermediate shaft.
      Fig 87: Identifying Flange, Discs, Plates And Cushion Plate
      G04976150Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  68. INSPECT DIRECT MULTIPLE DISC CLUTCH DISC  (See INSPECTION )
  69. REMOVE OVERDRIVE DIRECT CLUTCH DISC 
    1. Using a screwdriver, remove the snap ring from the intermediate shaft.
    2. Remove the flange, 3 discs and 3 plates from the intermediate shaft.
      Fig 88: Identifying Flange, Discs And Plates
      G04976151Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  70. INSPECT OVERDRIVE DIRECT CLUTCH DISC  (See INSPECTION )
  71. REMOVE OVERDRIVE CLUTCH RETURN SPRING SUB-ASSEMBLY 
    1. Place SST on the clutch balancer and compress the spring with a press.

      SST 09387-00020 

    2. Using a snap ring expander, remove the snap ring from the direct clutch drum.
      NOTE:
      • Stop the press when the spring seat is lowered 1 to 2 mm (0.0393 to 0.0787 in.) from the snap ring groove. This prevents the spring seat from being deformed.
      • Do not expand the snap ring excessively.
      Fig 89: Placing SST On Clutch Balancer And Compressing Spring With Press
      G04976152Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Remove the clutch balancer from the overdrive direct clutch drum.
      Fig 90: Identifying Clutch Balancer And Overdrive Direct Clutch Drum
      G06011703Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Remove the overdrive clutch return spring from the overdrive direct clutch drum.
      Fig 91: Identifying Overdrive Clutch Return Spring And Overdrive Direct Clutch Drum
      G04976154Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  72. INSPECT OVERDRIVE CLUTCH RETURN SPRING SUB-ASSEMBLY  (See INSPECTION )
  73. REMOVE OVERDRIVE DIRECT CLUTCH PISTON 
    1. Install the intermediate shaft to the transaxle rear cover.
    2. Holding the direct clutch piston by hand, apply compressed air (392 kPa, 4.0 kgf/cm2 , 57 psi) to the transaxle rear cover to remove the direct clutch piston.
      Fig 92: Applying Compressed Air To Transaxle Rear Cover
      G04976155Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  74. REMOVE OVERDRIVE DIRECT CLUTCH DRUM SUB-ASSEMBLY 
    1. Holding the overdrive direct clutch drum by hand, apply compressed air (392 kPa, 4.0 kgf/cm2 , 57 psi) to the transaxle rear cover to remove the direct clutch drum.
      Fig 93: Applying Compressed Air To Transaxle Rear Cover
      G04976156Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  75. REMOVE OVERDRIVE DIRECT CLUTCH O-RING 
    1. Using a screwdriver, remove the O-ring from the overdrive direct clutch drum.
      Fig 94: Locating Overdrive Direct Clutch O-Ring
      G04976157Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  76. REMOVE OVERDRIVE DIRECT CLUTCH HUB SUB-ASSEMBLY 
    1. Remove the thrust bearing race, thrust bearing, and overdrive direct clutch hub from the planetary gear assembly.
      Fig 95: Identifying Thrust Bearing Race, Thrust Bearing, And Overdrive Direct Clutch Hub
      G06011708Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  77. REMOVE REAR PLANETARY SUN GEAR ASSEMBLY 
    1. Remove the rear planetary sun gear assembly from the transaxle case.
      Fig 96: Identifying Rear Planetary Sun Gear Assembly
      G06011709Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the thrust needle roller bearing and thrust bearing race from the rear planetary sun gear assembly.
      Fig 97: Identifying Thrust Needle Roller Bearing
      G04976160Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Remove the No. 2 planetary carrier thrust washer from the rear planetary sun gear assembly.
      Fig 98: Identifying No. 2 Planetary Carrier Thrust Washer And Rear Planetary Sun Gear Assembly
      G06011711Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  78. REMOVE ONE-WAY CLUTCH ASSEMBLY 
    1. Remove the one-way clutch assembly and the thrust needle roller bearing from the transaxle case.
      Fig 99: Identifying One-Way Clutch Assembly And Thrust Needle Roller Bearing
      G06011712Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the one-way clutch inner race from the one-way clutch assembly.
      Fig 100: Identifying One-Way Clutch Inner Race
      G06011713Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  79. REMOVE ONE-WAY CLUTCH SLEEVE 
    1. Remove the one-way clutch sleeve from the transaxle case.
      Fig 101: Identifying One-Way Clutch Sleeve
      G06011714Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  80. REMOVE NO. 1 PLANETARY CARRIER THRUST WASHER 
    1. Remove the No. 1 planetary carrier thrust washer from the planetary gear assembly.
      Fig 102: Identifying No. 1 Planetary Carrier Thrust Washer
      G06011715Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  81. REMOVE 2ND BRAKE DISC 
    1. Using a screwdriver, remove the snap ring.
      Fig 103: Identifying Snap Ring
      G04976166Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the flange, 3 discs and 3 plates from the transaxle case.
  82. INSPECT 2ND BRAKE DISC  (See INSPECTION )
  83. REMOVE 2ND BRAKE PISTON ASSEMBLY 
    1. Using a screwdriver, remove the snap ring.
      Fig 104: Removing/Installing Snap Ring
      G04976257Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the 2nd brake piston assembly from the transaxle case.
      Fig 105: Identifying 2nd Brake Piston Assembly
      G06011718Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  84. REMOVE 2ND BRAKE PISTON RETURN SPRING SUB-ASSEMBLY 
    1. Place SST on the return spring and compress it with a press.

      SST 09387-00060 

    2. Using a screwdriver, remove the snap ring.
      Fig 106: Removing/Installing Snap Ring
      G04976169Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Remove the 2nd brake piston return spring sub-assembly.
      Fig 107: Identifying 2nd Brake Piston Return Spring Sub-Assembly
      G06011720Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  85. INSPECT 2ND BRAKE PISTON RETURN SPRING SUB-ASSEMBLY  (See INSPECTION )
  86. REMOVE 2ND BRAKE PISTON 
    1. Hold the 2nd brake piston and apply compressed air (392 kPa, 4.0 kgf/cm2 , 57 psi) to the 2nd brake cylinder to remove the 2nd brake piston.
      Fig 108: Applying Compressed Air To 2nd Brake Cylinder
      G05000982Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  87. REMOVE 2ND BRAKE PISTON O-RING 
    1. Remove the 2 O-rings from the 2nd brake piston.
      Fig 109: Locating O-Rings
      G04976172Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  88. REMOVE REAR PLANETARY GEAR ASSEMBLY 
    1. Using a screwdriver, remove the snap ring.
      Fig 110: Removing/Installing Snap Ring
      G04976173Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the rear planetary gear assembly from the transaxle case.
      Fig 111: Identifying Rear Planetary Gear Assembly
      G06011724Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  89. REMOVE INPUT SUN GEAR 
    1. Remove the 2 thrust needle roller bearings, No. 2 thrust bearing races, No. 3 thrust bearing race, and input sun gear from the transaxle case.
      Fig 112: Identifying Thrust Needle Roller Bearings, No. 2 Thrust Bearing Races, No. 3 Thrust Bearing Race And Input Sun Gear
      G06011725Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  90. REMOVE 1ST AND REVERSE BRAKE DISC 
    1. Remove the flange, 5 discs and 5 plates from the transaxle case.
      Fig 113: Identifying Flange, Discs And Plates
      G04976176Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  91. INSPECT 1ST AND REVERSE BRAKE DISC  (See INSPECTION )
  92. REMOVE FRONT PLANETARY GEAR ASSEMBLY 
    1. Using a chisel and a hammer, unstake the washer.
      NOTE: Push down all claws of the washer. Otherwise SST cannot be fully pressed against and loosen the nut.
      Fig 114: Unstaking Washer
      G04976177Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using SST, remove the nut and washer.

      SST 09387-00030,09387-00080 

      Fig 115: Removing/Installing Nut And Washer
      G04976178Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Using SST and a press, remove the front planetary gear assembly from the counter drive gear.

      SST 09950-60010 (09951-00450), 09950-70010 (09951-07100) 

      Fig 116: Removing Front Planetary Gear Assembly From Counter Drive Gear
      G04976179Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Remove the front planetary gear assembly from the brake hub.
      Fig 117: Identifying Front Planetary Gear Assembly And Brake Hub
      G04976243Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  93. REMOVE FRONT PLANETARY RING GEAR 
    1. Using a screwdriver, remove the snap ring and front planetary ring gear from the brake hub.
      Fig 118: Identifying Snap Ring And Front Planetary Ring Gear And Brake Hub
      G06011731Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  94. REMOVE 1ST AND REVERSE BRAKE RETURN SPRING SUB-ASSEMBLY 
    1. Place SST on the return spring, and compress the return spring with a press.

      SST 09387-00070 

      Fig 119: Compressing Return Spring With Press
      G04976182Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using a snap ring expander, remove the snap ring.
      NOTE:
      • Stop the press when the spring seat is lowered 1 to 2 mm (0.0393 to 0.0787 in.) from the snap ring groove. This prevents the spring seat from being deformed.
      • Do not expand the snap ring excessively.
    3. Remove the return spring.
  95. INSPECT 1ST AND REVERSE BRAKE RETURN SPRING SUB-ASSEMBLY  (See INSPECTION )
  96. REMOVE 1ST AND REVERSE BRAKE PISTON 
    1. Apply compressed air (392 kPa, 4.0 kgf/cm2 , 57 psi) to the transaxle case to remove the 1st and reverse brake piston.
      NOTE:
      • Applying compressed air may cause the piston to jump out. When removing the piston, hold it by hand using a piece of cloth.
      • Do not splash ATF when applying compressed air.
        Fig 120: Applying Compressed Air To Transaxle Case
        G06011733Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the 2 O-rings from the 1st and reverse brake piston.
      Fig 121: Locating O-Rings
      G06011734Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  97. REMOVE COUNTER DRIVE GEAR BEARING 
    1. Using SST and a press, remove the counter drive gear from the transaxle case.

      SST 09950-60010 (09951-00590), 09950-70010 (09951-07100) 

      Fig 122: Removing Counter Drive Gear From Transaxle Case
      G05559356Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Tighten 2 service bolts evenly and make a clearance of approximately 20.0 mm (0.787 in.) between the counter drive gear and the inner race.
      Fig 123: Tightening Service Bolts
      G04976186Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Using SST, remove the tapered roller bearing inner race.

      SST 09950-00020, 09950-00030, 09950-60010 (09951-00590) 

      Fig 124: Removing Tapered Roller Bearing Inner Race
      G04976187Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  98. REMOVE COUNTER DRIVE ANGULAR BALL BEARING 
    1. Remove the bearing inner race (rear side) and angular ball (rear side).
      Fig 125: Identifying Bearing Inner Race (Rear Side) And Angular Ball (Rear Side)
      G04976188Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using SST, remove the bearing outer race (rear side) from the transaxle case.

      SST 09308-00010 

      Fig 126: Removing Bearing Outer Race (Rear Side) From Transaxle Case
      G04976189Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Remove the angular ball (front side).
      Fig 127: Identifying Angular Ball (Front Side)
      G04976190Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Using SST and a press, remove the bearing outer race (front side) from the transaxle case.

      SST 09950-60020 (09951-00810), 09950-70010 (09951-07200) 

      Fig 128: Removing Bearing Outer Race (Front Side)
      G04976191Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Using a screwdriver, remove the snap ring from the transaxle case.
      Fig 129: Removing Snap Ring From Transaxle Case
      G05559363Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  99. REMOVE UNDERDRIVE BRAKE RETURN SPRING SUB-ASSEMBLY 
    1. Place SST on the return spring, and compress the return spring with a press.

      SST 09387-00020 

      Fig 130: Compressing Return Spring With Press
      G04976193Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using a snap ring expander, remove the snap ring.
      NOTE:
      • Stop the press when the spring seat is lowered 1 to 2 mm (0.0393 to 0.0787 in.) from the snap ring groove. This prevents the spring seat from being deformed.
      • Do not expand the snap ring excessively.
    3. Remove the return spring.
  100. INSPECT UNDERDRIVE BRAKE RETURN SPRING SUB-ASSEMBLY  (See INSPECTION )
  101. REMOVE UNDERDRIVE BRAKE PISTON 
    1. Apply compressed air (392 kPa, 4.0 kgf/cm2 , 57 psi) to the transaxle case to remove the underdrive brake piston.
      NOTE:
      • Applying compressed air may cause the piston to jump out. When removing the piston, hold it by hand using a piece of cloth.
      • Do not splash ATF when applying compressed air.
        Fig 131: Applying Compressed Air To Transaxle Case
        G06011744Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the 2 O-rings from the underdrive brake piston.
      Fig 132: Locating O-Rings
      G06011745Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  102. REMOVE NEEDLE ROLLER BEARING 
    1. Using SST, remove the needle roller bearing from the transaxle case.

      SST 09387-00041 (09387-01010, 09387-01030, 09387-01040) 

      Fig 133: Removing Needle Roller Bearing From Transaxle Case
      G04976196Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  103. REMOVE UNDERDRIVE CLUTCH DRUM OIL SEAL RING 
    1. Remove the 2 oil seal rings from the transaxle case.
      Fig 134: Identifying Underdrive Clutch Drum Oil Seal Rings
      G06011747Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  104. REMOVE NO. 1 TRANSAXLE CASE PLUG 
    1. Remove the 2 No. 1 transaxle case plugs.
    2. Remove the O-ring from each No. 1 transaxle case plug.
      Fig 135: Identifying No. 1 Transaxle Case Plugs With O-Rings
      G04976198Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  105. REMOVE UNDERDRIVE CYLINDRICAL ROLLER BEARING 
    1. Using SST, remove the underdrive cylindrical roller bearing from the transaxle case.

      SST 09820-00031, 09950-40011 (09952-04010, 09954-04010, 09955-04061, 09957-04010), 09950-50013 (09951-05010, 09953-05020) 

      Fig 136: Removing Underdrive Cylindrical Roller Bearing
      G06044111Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  106. REMOVE UNDERDRIVE OUTPUT SHAFT OIL SEAL RING 
    1. Remove the oil seal ring from the transaxle housing.
      Fig 137: Identifying Underdrive Output Shaft Oil Seal Ring
      G06011750Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  107. REMOVE DIFFERENTIAL GEAR LUBE APPLY TUBE 
    1. Remove the bolt, transaxle apply tube clamp and differential gear lube apply tube from the transaxle housing.
      Fig 138: Identifying Transaxle Apply Tube Clamp And Differential Gear Lube Apply Tube
      G06011751Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
scientia non olet · About LEMON Manuals