Transaxle Disassembly
- Remove the bolt and speedometer driven hole cover sub-assembly. Remove and discard sensor "O" ring. Remove nut, washer and control lever. Using a screwdriver, unstake lock tab on nut. Remove 2 bolts and nut, and remove PNP switch. See Fig 1. Remove bolt and transaxle revolution sensor from top of transaxle. Remove and discard sensor "O" ring. Remove clip and breather hose. Remove breather plug and "O" ring.
- Remove oil line union and elbow. Remove and discard "O" rings from union and elbow. Remove 4 screw plugs from transaxle housing and transaxle case. Remove and discard "O" rings from plugs. Remove transaxle line pressure test plug from transaxle case. See Fig 1.
- Place transaxle on wooden blocks. Remove 19 bolts, oil pan and gasket. Remove 3 bolts and oil strainer. Remove and discard "O" ring from oil strainer. Remove bolt, lock plate and fluid temperature sensor. Disconnect 5 shift solenoid connectors. See Fig 2. Remove 2 bolts, detent spring cover and detent spring.
- Remove 13 valve body bolts. Note bolt length and location for reassembly reference. See Figure. Remove valve body assembly.
- Remove solenoid connector bolt, located above PNP switch. Remove transaxle wiring harness with solenoid connector from transaxle case. Remove and discard "O" ring from connector. See Fig 3.
- Remove 2 apply gaskets, check ball body and spring. See Fig 4. Remove brake drum gasket. See Fig 5. Using 57 psi (4 kg/cm2 ) of compressed air applied to transaxle case, remove direct clutch accumulator piston. See Fig 6. Cover piston with shop towel during removal. Remove accumulator spring.
- Using 57 psi (4 kg/cm2
) of compressed air applied to transaxle case, remove reverse clutch accumulator piston and spring, and 2nd brake accumulator piston and spring. Cover pistons with shop towel during removal. See Fig 7 and Fig 8
.
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
- Position transaxle case with oil pump assembly facing upward. Remove 14 transaxle housing bolts. Note bolt length and location during removal for reassembly reference. See Fig 9. Tap on circumference of transaxle housing with a plastic hammer to remove housing from transaxle case.
- Remove 2 bolts and transaxle housing oil separator from transaxle housing. See Fig 10. Remove bolt, bearing lock plate and differential gear apply tube from transaxle housing. See Fig 11. Using a dial indicator, measure and record input shaft end play. See Fig 12. End play should be .015-.051" (.37-1.29 mm).
- Remove 7 oil pump bolts and oil pump. Remove differential assembly. See Fig 13. Remove 2 apply gaskets from front of transaxle case. See Fig 15. Remove forward multiple disc clutch assembly from transaxle case. Remove thrust needle roller bearing from forward multiple disc clutch assembly. See Fig 14.
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
- Remove forward clutch hub and thrust needle roller bearing from transaxle case. Using a dial indicator, measure the end play of intermediate shaft. End play should be .008-.038" (.20-.97 mm).
- Remove 11 bolts from transaxle rear cover. If necessary, tap on circumference of rear cover with plastic hammer to remove cover from transaxle case. See Fig 13.
- Remove 4 apply gaskets. See Fig 18. Remove thrust needle roller bearing race and direct and reverse multiple disc clutch assembly. Remove 2nd coast and O/D brake flange, 2 discs and 3 plates. Note location of components during removal for reassembly reference. Using a screwdriver, remove snap ring. See Fig 13.
- Remove thrust needle roller bearing and race. Remove direct clutch hub and thrust needle roller bearing. Remove rear planetary sun gear and No. 1 one-way clutch. See Fig 13.
- Remove thrust washer No. 1 and thrust needle roller bearing from No. 1 one-way clutch. Separate rear planetary sun gear and No. 1 one-way clutch. Remove thrust washer No. 2 from rear planetary sun gear. See Fig 13.
- Using a screwdriver, remove 2nd brake snap ring. Remove 2 flanges, 4 discs and 3 plates. Note location of components during removal for reassembly reference. Remove 2nd brake piston sleeve. See Fig 13.
- Using a screwdriver, remove 2nd brake cylinder snap ring. Remove 2nd brake cylinder, No. 2 one-way clutch and rear planetary gear from transaxle case. Remove thrust needle roller bearing and 2 bearing races from rear planetary gear. Separate 2nd brake cylinder, No. 2 one-way clutch and rear planetary gear. See Fig 13.
- Remove retainer from No. 2 one-way clutch. See Fig 19. Remove front planetary sun gear and thrust needle roller bearing from transaxle case. Using a screwdriver, remove 1st/reverse brake snap ring. Remove 1st/reverse brake flange, 4 discs and 4 plates from transaxle case. Note location of components during removal for reassembly reference. See Fig 13.
- Using parking lock pawl, lock counter driven gear in position. See Fig 16. Using a hammer and chisel, unstake washer located on counter drive gear nut.
- Ensure all claws on washer are pushed down to allow socket to fit securely on nut. Using holding tool and socket, remove nut. See Fig 17.
- Using appropriate adapter and press, remove front planetary gear assembly. See Fig 13. Compress 1st/reverse brake piston spring. Using a screwdriver, remove snap ring from 1st/reverse brake. Remove piston spring. Using 57 psi (4 kg/cm2 ) of compressed air applied to transaxle case, remove 1st/reverse brake piston from case. See Fig 20. Cover piston with shop towel during removal.
- Install 2 bolts into counter drive gear threaded holes. Tighten bolts evenly and remove counter drive gear and front planetary sun gear. Remove thrust needle roller bearing from front planetary sun gear and tapered roller bearing from counter drive gear. See Fig 13 and Fig 14 .
- Remove 3 bolts, cam guide and parking lock pawl bracket. Using needle nose pliers, remove manual valve lever retainer spring. Using a hammer and chisel, unstake and remove spacer. Using a pin punch and hammer, drive out roll pin. Ensure pin does not fall into transaxle case. See Fig 3.
- Remove manual valve lever shaft and manual valve lever. Remove parking lock pawl rod from manual valve lever. Using a screwdriver, remove shaft oil seal. See Fig 3. Remove torsion spring, shaft and parking lock pawl. See Fig 14.
- Remove counter driven gear, differential drive pinion and thrust needle roller bearing from transaxle case. See Fig 14.
- Using appropriate driver and a hammer, remove transaxle housing oil seal. Using a screwdriver and a hammer, remove bearing outer race. Using appropriate puller, remove cylindrical roller bearing and thrust needle bearing from transaxle housing. See Fig 14.
- Using appropriate puller, remove transaxle case roller bearing, bearing outer race and shim from transaxle case. See Fig 14. Using appropriate driver and a hammer, remove transaxle case oil seal. Remove 4 screw plugs and "O" rings from transaxle rear cover. See Figure.
CAUTION:
Use caution when removing transaxle housing. Differential assembly may attach to transaxle housing during removal.