Automatic Transaxle Unit: Disassembly

1. Remove the nut, washer and control shaft lever.
   Fig 1: Identifying 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: Removing Lock Nut And Nut Stopper

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3. Remove the 2 bolts and pull out the park/neutral position switch.

Fig 3: Identifying 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 Oil Cooler Tube Union (Inlet Oil Cooler Union)

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

Fig 5: Identifying Oil Cooler Tube Union (Outlet Oil Cooler Union)

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

Fig 6: Removing Bolts And Speed Sensors From Transaxle Assembly

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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: Removing O-Rings From 4 Transaxle Case

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1. Fix the transaxle assembly.

Fig 8: Identifying Automatic Transaxle Assembly

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

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2. Remove the 2 magnets from the oil pan.

Fig 10: Identifying Oil Pan Magnets

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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 Transmission Oil Cleaner Magnet

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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: Disconnecting Transmission Wire Connectors

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

Fig 13: Removing Transmission Wire Bolt

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

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2. Remove the O-ring from the oil strainer.

Fig 15: Removing O-Ring From Oil Strainer

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

Fig 16: Removing Transmission Valve Body Bolts

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

Fig 17: Removing Governor Apply Gasket From Transaxle Case

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

Fig 18: Removing Transaxle Case 2nd Brake Gasket From Transaxle Case

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

Fig 19: Removing Brake Drum Gasket From Transaxle Case

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

Fig 20: Removing Check Ball Body And Spring From Transaxle Case

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

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2. Apply compressed air (392 kPa, 4.0 kgf/sm² , 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

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

Fig 23: Removing O-Ring From C-3 Accumulator Piston

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1. Apply compressed air (392 kPa, 4.0 kgf/sm² , 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: Applying Compressed Air To Oil Hole

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Remove the 2 O-rings from the reverse clutch accumulator piston.

Fig 25: Removing O-Rings From Reverse Clutch Accumulator Piston

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1. Apply compressed air (392 kPa, 4.0 kgf/sm² , 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

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Remove the O-ring from the B-3 accumulator piston.

Fig 27: Removing O-Ring From 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: Removing Bolts, Manual Detent Spring Sub-Assembly And Cover

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

Fig 30: Removing 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

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2. Using a pin punch (diameter 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

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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: Removing Parking Lock Rod From Manual Valve Lever

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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.

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

Fig 35: Fixing Transaxle Case With Oil Pump Side Facing Up

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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: Removing Transaxle Housing Bolts

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

Fig 37: Removing Bolts And Oil Pump From Transaxle Case

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

Fig 38: Removing Thrust Needle Roller Bearing From Underdrive Planetary Gear Assembly

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

Fig 39: Removing Thrust Bearing Underdrive Race From Underdrive Planetary Gear Assembly

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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 From Transaxle Case

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1. Remove the forward clutch assembly from the transaxle case.
   Fig 42: Removing Forward Clutch Assembly From Transaxle Case

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

Fig 43: Removing Thrust Needle Roller Bearing From Forward Clutch

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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: Removing Multiple Disc Clutch Hub

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

HINT:

(See INSPECTION  )

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

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Remove the parking lock pawl shaft.
   Fig 46: Removing 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: Pushing 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 From Transaxle Case

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

Fig 49: Removing 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: Removing Underdrive Clutch Assembly

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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 From Transaxle Case

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Remove the underdrive 1-way clutch from the transaxle case.
   Fig 52: Removing Underdrive 1-Way Clutch From Transaxle Case

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Remove the outer race retainer from the 1-way clutch.

Fig 53: Removing Outer Race Retainer From 1-Way Clutch

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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.

Fig 55: Removing Flange, Discs And Plates From Transaxle Case

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

HINT:

(See INSPECTION  )

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: Removing Transaxle Rear Cover Sub-Assembly

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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: Removing O-Rings From Transaxle Case

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

Fig 58: Removing Rear Clutch Oil Seal Rings From Transaxle Rear Cover

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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: Removing 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: Removing 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: Removing Thrust Bearing And Direct Clutch Assembly From Transaxle Case

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

HINT:

(See INSPECTION  )

Fig 63: Removing Thrust Bearing Race, Thrust Bearing And Overdrive Direct Clutch Hub From Planetary Gear Assembly

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

   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: Removing Thrust Needle Roller Bearing And Thrust Bearing Race From Rear Planetary Sun Gear Assembly

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

Fig 66: Removing Planetary Carrier Thrust Washer

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

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Remove the 1-way clutch inner race from the 1-way clutch 341 assembly.

Fig 68: Removing 1-Way Clutch Inner Race From 1-Way Clutch 341 Assembly

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

Fig 69: Removing 1-Way Clutch Sleeve Outer From Transaxle Case

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

Fig 70: Removing Planetary Carrier Thrust Washer

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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: Removing 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: Removing 2ND Brake Piston Assembly From Transaxle Case

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

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Remove the rear planetary gear assembly from the transaxle case.

Fig 75: Removing Rear Planetary Gear Assembly From Transaxle Case

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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: Removing Thrust Needle Roller Bearings And Thrust Bearing Race

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

Fig 77: Identifying 1st And Reverse Brake Clutch Disc

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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 Front Planetary Gear Assembly Nut

   Courtesy 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 80: Identifying Front Planetary Gear Assembly From Counter Drive Gear

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Remove the front planetary gear assembly from the brake hub.

Fig 81: Removing Front Planetary Gear Assembly From Brake Hub

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

Fig 82: Removing Snap Ring And Front Planetary Ring Gear From Brake Hub

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

   SST 09387-00070 

   Fig 83: Compressing Return Spring With Press

   Courtesy 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 (0.039 to 0.078 in.) from the snap ring groove, to prevent the spring seat from being deformed.
   • Do not expand the snap ring excessively.

HINT:

(See INSPECTION  )

1. Apply compressed air (392 kPa, 4.0 kgf/sm² , 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 To Transaxle Case

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

Fig 85: Removing O-Rings From 1st And Reverse Brake Piston

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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: Removing Counter Drive Gear From Transaxle Case

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. As shown in the illustration, tighten the 2 bolts evenly and make 352 clearance of approx. 20.0 mm (0.787 in.) between the counter drive gear and the inner race.
   Fig 87: Tightening Counter Drive Gear Bolts

   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

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using SST and a press, remove the bearing outer race.

   SST 09950-60020 (09951-00910) 

   Fig 90: Removing Bearing Outer Race

   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 With Press

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

HINT:

(See INSPECTION  )

1. Apply compressed air (392 kPa, 4.0 kgf/sm² , 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: Removing O-Rings From Underdrive Brake Piston

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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 From Transaxle Case

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

Fig 95: Removing Oil Seal Rings From Transaxle Case

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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 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: Removing Underdrive Output Shaft Oil Sear 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: Removing Differential Gear Lube Apply Tube

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002