Automatic Transmission Unit: Disassembly

REMOVE TRANSMISSION CONTROL SHAFT LEVER RH
1. Remove the nut and transmission control shaft lever.
  
  Fig 1: Locating Transmission Control Shaft Lever Nut
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE PARK/NEUTRAL POSITION SWITCH ASSEMBLY
1. Using a screwdriver, bend the tabs of the lock washer.
2. Remove the nut and lock washer.
3. Remove the bolt and park/neutral position switch.
  
  Fig 2: Identifying Park/Neutral Position Switch Assembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE OIL COOLER TUBE UNION
1. Remove the 2 oil cooler tube unions.
2. Remove the O-rings from the oil cooler tube unions.
  
  Fig 3: Removing Oil Cooler Tube Union
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE NO. 1 BREATHER PLUG

Fig 4: Locating No. 1 Breather Plug
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE AUTOMATIC TRANSMISSION FLANGE YOKE ASSEMBLY
1. Using SST and a hammer, loosen the staked part of the nut.
  SST 09930-00010
  
  Fig 5: Removing Automatic Transmission Flange Yoke Nut
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using SST and a 30 mm socket wrench, remove the nut.
  SST 09330-00021, 09950-30012 (09955-03040)
3. Remove SST.
4. Tap the flange yoke with a plastic-faced hammer to remove it.
5. Remove the 2 output shaft rear bearing No. 1 spacers and rear cover sleeve.
  
  Fig 6: Removing Output Shaft Rear Bearing No. 1 Spacers And Rear Cover Sleeve
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
6. Using a screwdriver, pry out the oil seal from the flange yoke.
REMOVE AUTOMATIC TRANSMISSION OIL PAN SUB-ASSEMBLY
NOTE: Do not turn the transmission over as this will contaminate the valve body with foreign matter located at the bottom of the pan.
1. Remove the overflow plug and gasket.
2. Remove the drain plug and gasket.
  
  Fig 7: Identifying Oil Seal Of Flange Yoke
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Remove the 9 bolts, oil pan and gasket.
  
  Fig 8: Locating Automatic Transmission Oil Pan Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Examine the particles in the pan.
  1. Remove the magnets from the oil pan. Use the removed magnets to collect any steel chips. Look carefully at the chips and particles in the pan and on the magnet to anticipate the type of wear which might be found in the transmission. Steel (magnetic): bearing, gear and plate wear Brass (non-magnetic): bush wear
    
    Fig 9: Examining Particles In Pan
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE VALVE BODY OIL STRAINER ASSEMBLY
1. Remove the 4 bolts and valve body oil strainer from the valve body.
  
  Fig 10: Locating Valve Body Oil Strainer Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Remove the O-ring from the valve body oil strainer.
  
  Fig 11: Identifying O-Ring And Valve Body Oil Strainer
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE TRANSMISSION VALVE BODY ASSEMBLY
1. Remove the bolt, lock plate and ATF temperature sensor.
2. Remove the O-ring from the ATF temperature sensor.
3. Disconnect the 8 connectors from the solenoid valves.
  
  Fig 12: Locating Solenoid Valves Connectors
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Remove the bolt, detent spring cover and detent spring.
  
  Fig 13: Locating Detent Spring And Bolt
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
5. Remove the 17 bolts.
6. Remove the valve body.
7. Disconnect the lever pin from the manual valve.
  
  Fig 14: Locating Valve Body And Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE CHECK BALL BODY
1. Remove the check ball body and spring.
  
  Fig 15: Identifying Check Ball Body And Spring
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE TRANSMISSION WIRE
1. Disconnect the 3 connectors from the 3 speed sensors.
  
  Fig 16: Locating Speed Sensor Connectors
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Remove the bolt and pull out the transmission wire.
3. Remove the O-ring from the transmission wire connector.
  
  Fig 17: Locating Transmission Wire Bolt
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE SPEED SENSOR
1. Remove the 2 bolts and 2 speed sensors NC3 and SP2.
2. Using a T30 "TORX" wrench, remove the bolt and speed sensor NT.
3. Remove the O-ring from the speed sensor NT.
  
  Fig 18: Locating Speed Sensor Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE AUTOMATIC TRANSMISSION CASE PLUG
1. Remove the plug and O-ring.
  
  Fig 19: Locating Plug And O-Ring
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE PARKING LOCK PAWL BRACKET
1. Remove the 3 bolts and parking lock pawl bracket.
  
  Fig 20: Locating Parking Lock Pawl Bracket Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE PARKING LOCK ROD SUB-ASSEMBLY
1. Disconnect the parking lock rod from the manual valve lever.
  
  Fig 21: Removing Parking Lock Rod Sub-Assembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE PARKING LOCK PAWL SHAFT
1. Pull out the parking lock pawl shaft from the front side, then remove the lock pawl and spring.
2. Remove the E-ring from the shaft.
  
  Fig 22: Removing Parking Lock Pawl Shaft
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE MANUAL VALVE LEVER SUB-ASSEMBLY
1. Using a screwdriver and hammer, cut off the spacer and remove it from the shaft.
  
  Fig 23: Removing Manual Valve Lever Sub-Assembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using a pin punch and hammer, tap out the spring pin.
  HINT:
  
  Slowly tap 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 Spring Pin
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE MANUAL VALVE LEVER SHAFT OIL SEAL
1. Using a screwdriver, pry out the oil seal.
  
  Fig 25: Prying Oil Seal
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE OIL PUMP ASSEMBLY
1. Remove the 11 bolts from the transmission case.
  
  Fig 26: Locating Transmission Case Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Pull out the oil pump.
  NOTE: Do not damage the oil pump.
  
  Fig 27: Identifying Oil Pump
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Remove the O-ring from the oil pump.
  
  Fig 28: Identifying O-Ring From Oil Pump
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE OVERDRIVE AND REVERSE MULTIPLE DISC CLUTCH ASSEMBLY AND FRONT PLANETARY GEAR ASSEMBLY WITH NO. 1 BRAKE DISC SET
1. Remove the overdrive and reverse multiple disc clutch assembly and front planetary gear with No. 1 brake disc set from the transmission case.
2. Remove the thrust needle roller bearing and race.
  
  Fig 29: Identifying Reverse Multiple Disc Clutch Assembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE NO. 1 BRAKE DISC SET
1. Remove the 5 plates, 5 discs and flange.
INSPECT NO. 1 BRAKE DISC (See INSPECTION )
REMOVE FRONT PLANETARY GEAR ASSEMBLY
1. Remove the front planetary gear with the front planetary sun gear from the overdrive and reverse multiple disc clutch assembly.
  
  Fig 31: Identifying Front Planetary Gear Assembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Remove the 3 oil seal rings.
  
  Fig 32: Identifying Oil Seal Rings
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Remove the planetary carrier thrust washer.
  
  Fig 33: Identifying Planetary Carrier Thrust Washer
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Remove the 2 clutch drum oil seal rings.
  
  Fig 34: Identifying Clutch Drum Oil Seal Rings
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
5. Remove the front planetary sun gear.
INSPECT FRONT PLANETARY GEAR ASSEMBLY (See INSPECTION )
REMOVE NO. 3 CLUTCH DISC SET
1. Using a screwdriver, remove the hole snap ring from the overdrive direct clutch drum.
  
  Fig 36: Removing No. 3 Clutch Disc Set
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Remove the flange, 4 discs and 4 plates from the drum.
INSPECT NO. 3 CLUTCH DISC (See INSPECTION )
REMOVE REVERSE CLUTCH DISC SET
1. Using a screwdriver, remove the hole snap ring from the No. 2 reverse clutch drum.
  
  Fig 38: Removing Reverse Clutch Disc Set
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Remove the flange, 5 discs, 5 plates and cushion plate from the drum.
INSPECT REVERSE CLUTCH DISC (See INSPECTION )
REMOVE REVERSE CLUTCH PISTON
1. Place SST on the reverse clutch balancer, and compress the return spring with a press.
  SST 09380-50010
2. Using SST, remove the snap ring.
  SST 09350-30020 (09350-07070)
  
  Fig 40: Compressing Clutch Balancer With Press
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Remove the reverse piston balancer and reverse clutch piston return spring from the drum.
  
  Fig 41: Identifying Piston Balancer And Clutch Piston
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Hold the clutch piston and apply compressed air to the oil hole of the drum to remove the clutch piston.
5. Remove the O-ring from the piston.
INSPECT REVERSE CLUTCH RETURN SPRING SUB-ASSEMBLY (See INSPECTION )
REMOVE REVERSE CLUTCH DRUM SUB-ASSEMBLY
1. Remove the reverse clutch drum from the overdrive direct clutch drum.
  HINT:
  
  The reverse clutch drum is easier to remove if a hole snap ring is installed. Use the hole snap ring from the "REMOVE REVERSE CLUTCH DISC SET" procedure.
2. Remove the 3 O-rings from the reverse clutch drum.
  
  Fig 43: Removing Reverse Clutch Drum Sub-Assembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE NO. 3 CLUTCH PISTON
1. Place SST on the reverse clutch balancer, and compress the return spring with a press.
  SST 09380-50010
2. Using SST, remove the snap ring.
  SST 09350-30020 (09350-07070)
  
  Fig 44: Compressing Clutch Balancer With Press
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Remove the No. 3 clutch balancer and overdrive clutch return spring sub-assembly.
  
  Fig 45: Identifying No. 3 Clutch Balancer And Clutch Return Spring Sub-Assembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Hold the clutch piston and apply compressed air to the oil hole of the drum to remove the clutch piston.
5. Remove the O-ring from the balancer.
6. Remove the O-ring from the piston.
7. Remove the O-ring from the overdrive direct clutch drum sub-assembly.
INSPECT OVERDRIVE CLUTCH RETURN SPRING SUB-ASSEMBLY (See INSPECTION )
INSPECT NO. 3 CLUTCH DRUM SUB-ASSEMBLY (See INSPECTION )
REMOVE FORWARD MULTIPLE DISC CLUTCH ASSEMBLY WITH FRONT PLANETARY RING GEAR
1. Remove the forward multiple disc clutch assembly with front planetary ring gear, thrust needle roller bearing and race from the transmission case.
  
  Fig 47: Identifying Forward Multiple Clutch Disc Assembly With Front Planetary Ring Gear
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using needle-nose pliers, detach the snap ring and remove the ring gear and snap ring from the forward multiple disc clutch assembly.
  
  Fig 48: Identifying Stator Shaft Clutch Drum Thrust Washer
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE FORWARD MULTIPLE CLUTCH DISC SET
1. Using a screwdriver, remove the snap ring.
  
  Fig 49: Removing Snap Ring
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Remove the flange, 6 discs, 6 plates and cushion plate.
INSPECT FORWARD MULTIPLE CLUTCH DISC (See INSPECTION )
REMOVE FORWARD CLUTCH PISTON
1. Place SST on the No. 1 clutch balancer, and compress the return spring with a press.
  SST 09380-50010
2. Using SST, remove the snap ring.
  SST 09350-30020 (09350-07070)
  
  Fig 51: Compressing Clutch Balancer With Press
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Remove the No. 1 clutch balancer and forward clutch return spring sub-assembly from the drum.
4. Remove the O-ring from the balancer.
  
  Fig 52: Identifying Clutch Balancer And Forward Clutch Return Spring Sub-Assembly From Forward Clutch Drum Sub-Assembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
5. Hold the clutch piston and apply compressed air to the oil hole of the drum to remove the clutch piston.
6. Remove the 2 O-rings from the piston.
INSPECT FORWARD CLUTCH RETURN SPRING SUB-ASSEMBLY (See INSPECTION )
INSPECT FORWARD CLUTCH DRUM SUB-ASSEMBLY (See INSPECTION )
REMOVE MULTIPLE DISC CLUTCH HUB
1. Remove the clutch hub from the transmission case.
2. Remove the thrust bearing race and thrust needle roller bearing from the transmission case.
  
  Fig 54: Identifying Multiple Disc Clutch Hub
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE SUN GEAR INPUT DRUM SUB-ASSEMBLY
1. Remove the sun gear input drum, thrust needle roller bearing and race from the transmission case.
INSPECT SUN GEAR INPUT DRUM SUB-ASSEMBLY (See INSPECTION )
REMOVE 1-WAY CLUTCH OUTER RACE WITH NO. 1 1-WAY CLUTCH
1. Using SST, remove the snap ring from the transmission case.
  SST 09350-30020 (09350-07060)
  
  Fig 56: Identifying Snap Ring From Transmission Case
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Remove the 1-way clutch outer race with 1-way clutch.
  
  Fig 57: Identifying 1-Way Clutch Outer Race With 1-Way Clutch
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE REAR PLANETARY SUN GEAR ASSEMBLY
1. Remove the sun gear and thrust bearing race from the transmission case.
INSPECT REAR PLANETARY SUN GEAR ASSEMBLY (See INSPECTION )

Fig 58: Identifying Rear Planetary Sun Gear Assembly
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE REAR PLANETARY GEAR ASSEMBLY
1. Remove the thrust needle roller bearing, rear planetary gear assembly and thrust bearing races from the transmission case.
INSPECT NO. 1 1-WAY CLUTCH (See INSPECTION )
REMOVE NO. 1 1-WAY CLUTCH
1. Remove the 2 snap rings from the outer race.
INSPECT REAR PLANETARY GEAR ASSEMBLY (See INSPECTION )
REMOVE NO. 2 BRAKE DISC SET
1. Remove the No. 1 plate, 4 discs, 3 No. 2 plates and flange.
INSPECT NO. 2 BRAKE DISC (See INSPECTION )
REMOVE DIRECT CLUTCH ASSEMBLY WITH REAR PLANETARY RING GEAR AND OUTPUT SHAFT SUB-ASSEMBLY
1. Remove the 2 thrust needle bearings, 2 races, direct clutch assembly with rear planetary ring gear and output shaft from the transmission case.
  
  Fig 62: Identifying Thrust Needle Bearings
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE REAR PLANETARY RING GEAR
1. Using needle-nose pliers, detach the snap ring and disconnect the rear planetary ring gear from the output shaft.
  
  Fig 63: Detaching Snap Ring
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
DISCONNECT DIRECT CLUTCH ASSEMBLY
1. Disconnect the direct clutch drum from the output shaft and remove the thrust needle bearing and thrust bearing race from the output shaft.
  
  Fig 64: Identifying Direct Clutch Assembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Remove the 3 clutch drum oil seal rings from the output shaft.
  
  Fig 65: Identifying Clutch Drum Oil Seal Rings From Output Shaft
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Remove the 2 clutch drum oil seal rings from the direct clutch drum.
  
  Fig 66: Identifying Clutch Drum Oil Seal Rings From Direct Clutch Drum
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE NO. 2 CLUTCH DISC SET
1. Remove the snap ring and flange, 6 discs and 6 plates from the direct clutch drum.
INSPECT NO. 2 CLUTCH DISC (See INSPECTION )
REMOVE DIRECT CLUTCH PISTON
1. Place SST on the No. 2 clutch balancer, and compress the return spring with a press.
  SST 09387-00020
2. Using SST, remove the snap ring.
  SST 09350-30020 (09350-07070)
  
  Fig 68: Compressing Return Spring With Press
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Remove the No. 2 clutch balancer and direct clutch piston return spring sub-assembly from the drum.
4. Remove the O-ring from the balancer.
  
  Fig 69: Identifying Clutch Balancer And Direct Clutch Return Spring Sub-Assembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
5. Hold the clutch piston and apply compressed air to the oil hole of the direct clutch drum to remove the clutch piston.
6. Remove the O-ring from the piston.
7. Remove the O-ring from the direct clutch drum.
INSPECT DIRECT CLUTCH RETURN SPRING SUB-ASSEMBLY (See INSPECTION )
REMOVE NO. 2 BRAKE PISTON
1. Set SST on the brake piston return spring, tighten SST and compress the return spring.
  SST 09380-50010
2. Using SST, remove the snap ring and the brake return spring.
  SST 09350-30020 (09350-07070)
  
  Fig 71: Compressing Return Spring With SST
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Hold the brake piston and apply compressed air to the oil hole of the transmission case to remove the brake piston.
4. Remove the 3 O-rings from the brake piston.
INSPECT 2ND BRAKE PISTON RETURN SPRING SUB-ASSEMBLY (See INSPECTION )

Fig 72: Applying Compressed Air To Oil Hole Of Transmission Case
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE AUTOMATIC TRANSMISSION REAR OIL SEAL
1. Using SST, tap out the oil seal.
  SST 09308-00010
REMOVE OUTPUT SHAFT REAR RADIAL BALL BEARING
1. Using snap ring pliers, remove the snap ring from the transmission case.
  
  Fig 73: Removing Automatic Transmission Rear Oil Seal
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using SST, remove the bearing.
  SST 09308-00010
  
  Fig 74: Removing Output Shaft Rear Radial Ball Bearing
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002