Automatic Transaxle Unit: Disassembly

1. Remove the nut, washer and control shaft lever.
   Fig 1: Locating Nut, Washer And Control Shaft Lever

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2. Using a screwdriver, unstake the nut stopper, and remove the lock nut and nut stopper.
   Fig 2: Removal/Installation Of Lock Nut And Nut Stopper

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3. Remove the 2 bolts and pull out the park/neutral position switch.
   Fig 3: Locating Bolts And Park/Neutral Position Switch

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1. Remove the breather plug hose from the transaxle case.

1. Remove the union.
2. Remove the O-ring from the union.

Fig 4: Identifying O-Ring And Union

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1. Remove the elbow.
2. Remove the O-ring from the elbow.

Fig 5: Identifying O-Ring And Elbow

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1. Remove the 2 bolts and the 2 speed sensors from the transaxle assembly.

Fig 6: Identifying Bolts And Speed Sensors

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1. Remove the 4 transaxle case No.1 plugs from the transaxle case.
2. Remove the 4 O-rings from the 4 transaxle case No.1 plugs.

Fig 7: Identifying O-Rings And Transaxle Case No.1 Plugs

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1. Fix the transaxle assembly.

Fig 8: Fixing Automatic Transaxle Assembly

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1. Remove the 18 bolts, oil pan and gasket.
   Fig 9: Identifying Oil Pan Bolts And Gasket

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2. Remove the 2 magnets from the oil pan.
   Fig 10: Identifying Magnets In Oil Pan

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1. Remove the magnets and use them to collect any steel chips. Examine the chips and particles in the pan and on the magnet to determine what type of wear has occurred in the transaxle:

   Result: 

   Steel (magnetic): 

   Wear of the bearing, gear and plate 

   Brass (non-magnetic): 

   Wear of the bushing 

Fig 11: Inspecting Chips And Particles

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1. Remove the 7 connectors from the shift solenoid valves.
2. Remove the bolt, lock plate and temperature sensor.

Fig 12: Identifying Temperature Sensor

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1. Remove the bolt and transmission wire from the transaxle case.

Fig 13: Identifying Bolt And Transmission Wire

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1. Remove the 3 bolts and oil strainer.
   Fig 14: Locating Bolts And Oil Strainer

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2. Remove the O-ring from the oil strainer.
   Fig 15: Locating O-Ring

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1. Support the valve body assembly and remove the 17 bolts and valve body assembly.

Fig 16: Identifying Bolts And Valve Body Assembly

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1. Remove the governor apply gasket No.1 from the transaxle case.

Fig 17: Locating Governor Apply Gasket No.1

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1. Remove the transaxle case 2nd brake gasket from the transaxle case.

Fig 18: Locating Transaxle Case 2nd Brake Gasket

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1. Remove the brake drum gasket from the transaxle case.

Fig 19: Locating Brake Drum Gasket

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1. Remove the check ball body and spring from the transaxle case.

Fig 20: Identifying Check Ball Body And Spring

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1. Remove the spring from the C-3 accumulator piston.
   Fig 21: Identifying Spring And C-3 Accumulator Piston

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2. Apply compressed air (392 kPa, 4.0 kgf/cm² , 57 psi) to the oil hole and remove the C-3 accumulator piston.
   NOTE:

   • Applying compressed air may cause the piston to jump-out. When removing the piston, hold it using a waste cloth.
   • Take care not to splash ATF when applying compressed air.
   Fig 22: Applying Compressed Air To Oil Hole

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3. Remove the O-ring from the C-3 accumulator piston.

Fig 23: Locating O-Ring And C-3 Accumulator Piston

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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 using a waste cloth.
   • Take care not to splash ATF when applying compressed air.
   Fig 24: Locating Reverse Accumulator Piston And Spring

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2. Remove the 2 O-rings from the reverse clutch accumulator piston.

Fig 25: Locating O-Rings And Reverse Clutch Accumulator Piston

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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 using a waste cloth.
   • Take care not to splash ATF when applying compressed air.
   Fig 26: Applying Compressed Air To Oil Hole

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2. Remove the O-ring from the B-3 accumulator piston.

Fig 27: Locating O-Ring And B-3 Accumulator Piston

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1. Using needle-nose pliers, remove the manual valve lever shaft retainer spring.

Fig 28: Removing Manual Valve Lever Shaft Retainer Spring

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1. Remove the 2 bolts, the manual detent spring sub-assembly and cover.

Fig 29: Locating Bolts And Manual Detent Spring Sub-Assembly

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1. Remove the 2 bolts and parking lock pawl bracket.

Fig 30: Locating Bolts And Parking Lock Pawl Bracket

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1. Using a chisel and hammer, cut off and remove the spacer.
   Fig 31: Removing Spacer Using Chisel And Hammer

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2. Using a pin punch (35 mm) and hammer, drive out the pin.

   HINT:

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

   Fig 32: Driving Out Pin Using Pin Punch And Hammer

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3. Remove the manual valve lever shaft and manual valve lever.

Fig 33: Removing Manual Valve Lever Shaft And Manual Valve Lever

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1. Remove the parking lock rod from the manual valve lever.

Fig 34: Identifying Parking Lock Rod Sub-Assembly

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1. Using a screwdriver, remove the oil seal from the transaxle case.
   NOTE: Do not apply excessive force when removing the oil seal.

Fig 35: Removing Oil Seal From Transaxle Case

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1. Fix the transaxle case with the oil pump side facing up.

HINT:

(See INSPECTION )

1. Remove the 16 bolts.
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.

Fig 36: Locating Transaxle Housing Bolts

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1. Remove the 7 bolts and oil pump from the transaxle case.

Fig 37: Locating Oil Pump Assembly Bolts

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1. Remove the thrust needle roller bearing from the underdrive planetary gear assembly.

Fig 38: Identifying Thrust Needle Roller Bearing

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1. Remove the thrust bearing underdrive race No.2 from the underdrive planetary gear assembly.

Fig 39: Identifying Thrust Bearing Underdrive Race No.2

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1. Remove the differential gear assembly from the transaxle case.

Fig 40: Removing Differential Gear Assembly From Transaxle Case

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1. Remove the 2 overdrive brake gaskets from the transaxle case.

Fig 41: Removing Overdrive Brake Gaskets

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1. Remove the forward clutch assembly from the transaxle case.
   Fig 42: Identifying Forward Clutch Assembly

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2. Remove the thrust needle roller bearing from the forward clutch.

Fig 43: Identifying Thrust Needle Roller Bearing

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1. Remove the thrust needle roller bearing, multiple disc clutch hub, thrust needle roller bearing and thrust bearing race No. 1 from the transaxle case.

Fig 44: Identifying Thrust Needle Roller Bearing, Multiple Disc Clutch Hub And Thrust Needle Roller Bearing

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HINT:

(See INSPECTION )

1. Remove the bolt and pawl shaft clamp.
   Fig 45: Identifying Bolt And Pawl Shaft Clamp

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Remove the parking lock pawl shaft.
   Fig 46: Identifying Parking Lock Pawl Shaft

   Courtesy 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 47: Locating Parking Lock Pawl

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Remove the underdrive planetary gear assembly from the transaxle case.
   NOTE: Be careful so that the underdrive planetary gear assembly will not fall out.

Fig 48: Removing Underdrive Planetary Gear Assembly

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1. Remove the spring, pawl pin and parking lock pawl.

Fig 49: Identifying Spring, Pawl Pin And Parking Lock Pawl

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1. Remove the underdrive clutch assembly, thrust bearing and bearing race from the transaxle case.

Fig 50: Identifying Thrust Bearing And Bearing Race

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1. Using a screwdriver, remove the snap ring from the transaxle case.
   NOTE: Do not apply excessive force when removing the snap ring.
   Fig 51: Removing Snap Ring

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2. Remove the underdrive 1-way clutch from the transaxle case.
   Fig 52: Identifying Underdrive 1-Way Clutch

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3. Remove the outer race retainer from the 1-way clutch.

Fig 53: Identifying Outer Race Retainer

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1. Using a screwdriver, remove the snap ring.
   NOTE: Do not apply excessive force when removing the snap ring.
   Fig 54: Removing Snap Ring

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Remove the flange, 4 discs and 4 plates from the transaxle case.

HINT:

(See INSPECTION )

Fig 55: Identifying Flange

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1. Remove the 11 bolts.
2. Tap on the circumference of the rear cover with a plastic hammer to remove the transaxle rear cover from the transaxle case.

Fig 56: Locating Transaxle Rear Cover Bolts

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1. Remove the 4 transaxle case No.1 plugs from the transaxle rear cover.
2. Remove the 4 O-rings from the 4 transaxle case No.1 plugs.

Fig 57: Identifying O-Ring And Transaxle Case No. 1 Plugs

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1. Remove the 3 rear clutch oil seal rings from the transaxle rear cover.

Fig 58: Identifying Rear Clutch Oil Seal Ring Outer

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1. Using SST, remove the needle-roller bearing from the transaxle rear cover.

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

Fig 59: Removing Needle-Roller Bearing From Transaxle Rear Cover

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1. Using a screwdriver, remove the 3 apply gaskets.

Fig 60: Locating Governor Apply Gaskets

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1. Remove the bolt, clamp and brake apply tube.
2. Remove the clutch apply tube.
3. Remove the brake apply tube from the clamp.
   NOTE: Do not bend the tubes.

Fig 61: Locating Bolt, Clamp And Brake Apply Tube

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1. Remove the thrust bearing and the direct clutch assembly from the transaxle case.

Fig 62: Identifying Thrust Bearing And Direct Clutch Assembly

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1. Remove the thrust bearing race, thrust bearing and overdrive direct clutch hub from the planetary gear assembly.

Fig 63: Identifying Thrust Bearing Race, Thrust Bearing And Overdrive Direct Clutch Hub

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HINT:

(See INSPECTION )

1. Remove the rear planetary sun gear assembly from the transaxle case.
   Fig 64: Identifying Rear Planetary Sun Gear Assembly

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Remove the thrust needle roller bearing and thrust bearing race from the rear planetary sun gear assembly.
   Fig 65: Identifying Thrust Needle Roller Bearing And Thrust Bearing Race

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Remove the planetary carrier thrust washer No.2 from the rear planetary sun gear assembly.

Fig 66: Identifying Planetary Carrier Thrust Washer No.2 And Rear Planetary Sun Gear Assembly

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1. Remove the 1-way clutch assembly and the thrust needle roller bearing from the transaxle case.
   Fig 67: Identifying 1-Way Clutch Assembly And Thrust Needle Roller Bearing

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Remove the 1-way clutch inner race from the 1-way clutch assembly.

Fig 68: Identifying 1-Way Clutch Inner Race

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1. Remove the 1-way clutch sleeve outer from the transaxle case.

Fig 69: Identifying 1-Way Clutch Sleeve Outer

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1. Remove the planetary carrier thrust washer No.1 from the planetary gear assembly.

Fig 70: Identifying Planetary Carrier Thrust Washer No.1

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1. Using a screwdriver, remove the snap ring.
2. Remove the flange, 4 discs and 4 plates from the transaxle case.

Fig 71: Identifying Snap Ring

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HINT:

(See INSPECTION )

1. Using a screwdriver, remove the snap ring.
   Fig 72: Removing Snap Ring

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Remove the 2ND brake piston assembly from the transaxle case.

Fig 73: Identifying 2nd Brake Piston Assembly

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1. Using a screwdriver, remove the snap ring.
   Fig 74: Removing Snap Ring

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2. Remove the rear planetary gear assembly from the transaxle case.

Fig 75: Identifying Rear Planetary Gear Assembly

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1. Remove the 2 thrust needle roller bearings, thrust bearing race No.2 and the input sun gear from the transaxle case.

Fig 76: Identifying Thrust Needle Roller Bearings, Thrust Bearing Race No.2 And Input Sun Gear

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1. Remove the flange, 6 discs and 6 plates from the transaxle case.

Fig 77: Identifying Flange, Discs And Plates

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HINT:

(See INSPECTION )

1. Using a chisel and hammer, unstake the lock washer.
   NOTE: Push down all claws of the washer. Otherwise the SST cannot be fully pressed against the nut, and cannot loosen the nut.
   Fig 78: Unstaking Lock Washer

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using SST, remove the nut.

   SST 09387-00030, 09387-00080 

   Fig 79: Removing Nut

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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 80: Pressing Out Front Planetary Gear From Counter Drive Gear

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4. Remove the front planetary gear assembly from the brake hub.

Fig 81: Removing Front Planetary Gear Assembly

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1. Using a screwdriver, remove the snap ring and front planetary ring gear from the brake hub.

Fig 82: Identifying Snap Ring And Front Planetary Ring Gear

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1. Place SST on the return spring, and compress the return spring with a press.

   SST 09387-00070 

2. Using a snap ring expander, remove the snap ring.
   NOTE:

   • Stop the press when the spring seat is lowered 1 to 2 mm (0.039 to 0.078 in.) from the snap ring groove, to prevent the spring seat from being deformed.
   • Do not expand the snap ring excessively.

Fig 83: Compressing Return Spring

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HINT:

(See INSPECTION )

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 using a waste cloth.
   • Take care not to splash ATF when applying compressed air.
   Fig 84: Applying Compressed Air May

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Remove the 2 O-rings from the 1st and reverse brake piston.

Fig 85: Identifying O-Rings

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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 86: Identifying Counter Drive Gear

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. As shown in the illustration, tighten the 2 bolts evenly and make clearance of approx. 20.0 mm (0.787 in.) between the counter drive gear and the inner race.
   Fig 87: Identifying Clearance Between Counter Drive Gear And Inner Race

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Using SST, remove the tapered roller bearing.

   SST 09950-60010 (09951-00590), 09950-00020, 09950-00030, 09950-40011 (09957-04010) 

Fig 88: Removing Tapered Roller Bearing

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1. Using a snap ring expander, remove the snap ring.
   Fig 89: Removing Snap Ring

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2. Using SST and a press, remove the bearing outer race.

   SST 09950-60020 (09951-00910) 

Fig 90: Identifying Bearing Outer Race And SST

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Place SST on the return spring, and compress the return spring with a press.

   SST 09387-00020 

2. Using a snap ring expander, remove the snap ring.
   NOTE:

   • Stop the press when the spring seat is lowered 1 to 2 mm (0.039 to 0.078 in.) from the snap ring groove, to prevent the spring seat from being deformed.
   • Do not expand the snap ring excessively.
   Fig 91: Compressing Return Spring

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

HINT:

(See INSPECTION )

1. Apply compressed air (392 kPa, 4.0 kgf/cm² , 57 psi) to the transaxle case to remove the underdrive brake piston.
   Fig 92: Applying Compressed Air To Transaxle Case

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Remove the 2 O-rings from the underdrive brake piston.

Fig 93: Identifying O-Rings

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1. Using SST, remove the needle roller bearing from the transaxle case.

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

Fig 94: Removing Needle Roller Bearing

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1. Remove the 2 oil seal rings from the transaxle case.

Fig 95: Identifying Underdrive Clutch Drum Oil Seal Ring

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1. Remove the 2 transaxle case No.1 plugs.
2. Remove the 2 O-rings from the 2 transaxle case No.1 plugs.

Fig 96: Identifying O-Rings And Transaxle Case No 1 Plug

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1. Using SST, remove the underdrive cylindrical roller bearing from the transaxle case.

   SST 09514-35011 

Fig 97: Removing Underdrive Cylindrical Roller Bearing

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1. Remove the oil seal ring from the transaxle housing.

Fig 98: Identifying Underdrive Output Shaft Oil Seal Ring

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1. Remove the bolt, transaxle apply tube clamp and differential gear lube apply tube from the transaxle housing.
   NOTE: Do not bend the tubes.

Fig 99: Identifying Bolt, Transaxle Apply Tube Clamp And Differential Gear Lube Apply Tube

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