Automatic Transmission Unit: Disassembly

REMOVE TRANSMISSION CONTROL SHAFT LEVER RH

Fig 1: Locating Transmission Control Shaft Lever Nut
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
1. Remove the nut and transmission control shaft lever.
REMOVE PARK/NEUTRAL POSITION SWITCH ASSEMBLY

Fig 2: Identifying Park/Neutral Position Switch Bolt, Nut And Lock Washer
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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.
REMOVE OIL COOLER TUBE UNION

Fig 3: Identifying Oil Cooler Tube Unions
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
1. Remove the 2 oil cooler tube unions.
2. Remove the O-rings from the oil cooler tube unions.
REMOVE NO. 1 BREATHER PLUG

Fig 4: Locating No. 1 Breather Plug
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE AUTOMATIC TRANSMISSION FLANGE YOKE ASSEMBLY

Fig 5: Loosening Nut
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
1. Using SST and a hammer, loosen the staked part of the nut.
  SST 09930-00010
2. Using SST and a 30 mm socket wrench, remove the nut.
  
  Fig 6: Removing Nut
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  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.
6. Using a screwdriver, pry out the oil seal from the flange yoke.
  
  Fig 7: Identifying Oil Seal
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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.
3. Remove the 9 bolts, oil pan and gasket.
  
  Fig 8: Locating Oil Pan Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Examine the particles in the pan.
  
  Fig 9: Checking Chips And Particles In Pan
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  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
REMOVE VALVE BODY OIL STRAINER ASSEMBLY

Fig 10: Locating Valve Body Oil Strainer Assembly Bolts
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
1. Remove the 4 bolts and valve body oil strainer from the valve body.
2. Remove the O-ring from the valve body oil strainer.
  
  Fig 11: Identifying O-Ring
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE TRANSMISSION VALVE BODY ASSEMBLY

Fig 12: Locating Solenoid Valves Connectors
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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.
4. Remove the bolt, detent spring cover and detent spring.
  
  Fig 13: Identifying Bolt, Detent Spring Cover And Detent Spring
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
5. Remove the 17 bolts.
  
  Fig 14: Locating Valve Body Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
6. Remove the valve body.
7. Disconnect the lever pin from the manual valve.
REMOVE CHECK BALL BODY

Fig 15: Identifying Check Ball Body And Spring
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
1. Remove the check ball body and spring.
REMOVE TRANSMISSION WIRE

Fig 16: Locating Speed Sensor Connectors
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
1. Disconnect the 3 connectors from the 3 speed sensors.
2. Remove the bolt and pull out the transmission wire.
  
  Fig 17: Locating Transmission Wire Bolt
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Remove the O-ring from the transmission wire connector.
REMOVE SPEED SENSOR

Fig 18: Locating Speed Sensors NC3 And SP2
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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.
REMOVE AUTOMATIC TRANSMISSION CASE PLUG

Fig 19: Locating Automatic Transmission Case Plug
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
1. Remove the plug and O-ring.
REMOVE PARKING LOCK PAWL BRACKET

Fig 20: Locating Parking Lock Pawl Bracket Bolts
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
1. Remove the 3 bolts and parking lock pawl bracket.
REMOVE PARKING LOCK ROD SUB-ASSEMBLY

Fig 21: Disconnecting Parking Lock Rod
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
1. Disconnect the parking lock rod from the manual valve lever.
REMOVE PARKING LOCK PAWL SHAFT

Fig 22: Removing E-Ring
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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.
REMOVE MANUAL VALVE LEVER SUB-ASSEMBLY

Fig 23: Cutting Off Spacer
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
1. Using a screwdriver and hammer, cut off the spacer and remove it from the shaft.
2. Using a pin punch and hammer, tap out the spring pin.
  
  Fig 24: Tapping Out Spring Pin
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  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.
REMOVE MANUAL VALVE LEVER SHAFT OIL SEAL
1. Using a screwdriver, pry out the oil seal.
  
  Fig 25: Prying Out Oil Seal
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE OIL PUMP ASSEMBLY

Fig 26: Locating Transmission Case Bolts
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
1. Remove the 11 bolts from the transmission case.
2. Pull out the oil pump.
  
  Fig 27: Locating Oil Pump
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  NOTE: Do not damage the oil pump.
3. Remove the O-ring from the oil pump.
  
  Fig 28: Identifying Oil Pump O-Ring
  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

Fig 29: Identifying Thrust Needle Roller Bearing And Race
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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.
REMOVE NO. 1 BRAKE DISC SET

Fig 30: Identifying Plates, Discs And Flange
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
1. Remove the 5 plates, 5 discs and flange.
INSPECT NO. 1 BRAKE DISC (See INSPECTION )
REMOVE FRONT PLANETARY GEAR ASSEMBLY

Fig 31: Identifying Front Planetary Gear
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
1. Remove the front planetary gear with the front planetary sun gear from the overdrive and reverse multiple disc clutch assembly.
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.
  
  Fig 35: Identifying Front Planetary Sun Gear
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT FRONT PLANETARY GEAR ASSEMBLY (See INSPECTION )
REMOVE NO. 3 CLUTCH DISC SET

Fig 36: Identifying No. 3 Clutch Disc Snap Ring
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
1. Using a screwdriver, remove the hole snap ring from the overdrive direct clutch drum.
2. Remove the flange, 4 discs and 4 plates from the drum.
  
  Fig 37: Identifying Flange, Discs And Plates
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT NO. 3 CLUTCH DISC (See INSPECTION )
REMOVE REVERSE CLUTCH DISC SET

Fig 38: Identifying Reverse Clutch Disc Set Snap Ring
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
1. Using a screwdriver, remove the hole snap ring from the No. 2 reverse clutch drum.
2. Remove the flange, 5 discs, 5 plates and cushion plate from the drum.
  
  Fig 39: Identifying Flange, Discs, Plates And Cushion Plate
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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.
  
  Fig 40: Removing Snap Ring
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  SST 09350-30020 (09350-07070)
3. Remove the reverse piston balancer and reverse clutch piston return spring from the drum.
  
  Fig 41: Identifying Reverse Piston Balancer And Reverse Clutch Piston Return Spring
  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.
  
  Fig 42: Applying Compressed Air To Oil Hole Of Drum
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
5. Remove the O-ring from the piston.
INSPECT REVERSE CLUTCH RETURN SPRING SUB-ASSEMBLY (See INSPECTION )
REMOVE REVERSE CLUTCH DRUM SUB-ASSEMBLY

Fig 43: Removing Reverse Clutch Drum
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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.
REMOVE NO. 3 CLUTCH PISTON

Fig 44: Removing Snap Ring
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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)
3. Remove the No. 3 clutch balancer and overdrive clutch return spring sub-assembly.
  
  Fig 45: Identifying No. 3 Clutch Balancer And Overdrive Clutch Return Spring
  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.
  
  Fig 46: Applying Compressed Air To Oil Hole Of Drum
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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

Fig 47: Identifying Forward Multiple Disc Clutch Assembly
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
1. Remove the forward multiple disc clutch assembly with front planetary ring gear, thrust needle roller bearing and race from the transmission case.
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: Removing Snap Ring
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE FORWARD MULTIPLE CLUTCH DISC SET

Fig 49: Removing Snap Ring
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
1. Using a screwdriver, remove the snap ring.
2. Remove the flange, 6 discs, 6 plates and cushion plate.
  
  Fig 50: Identifying Flange, Discs, Plates And Cushion Plate
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT FORWARD MULTIPLE CLUTCH DISC (See INSPECTION )
REMOVE FORWARD CLUTCH PISTON

Fig 51: Removing Snap Ring
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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)
3. Remove the No. 1 clutch balancer and forward clutch return spring sub-assembly from the drum.
  
  Fig 52: Identifying No. 1 Clutch Balancer And Forward Clutch Return Spring Sub-Assembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Remove the O-ring from the balancer.
5. Hold the clutch piston and apply compressed air to the oil hole of the drum to remove the clutch piston.
  
  Fig 53: Applying Compressed Air To Oil Hole Of Drum
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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

Fig 54: Identifying Thrust Bearing Race And Thrust Needle Roller Bearing
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
1. Remove the clutch hub from the transmission case.
2. Remove the thrust bearing race and thrust needle roller bearing from the transmission case.
REMOVE SUN GEAR INPUT DRUM SUB-ASSEMBLY

Fig 55: Identifying Sun Gear Input Drum, Thrust Needle Roller Bearing
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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

Fig 56: Removing Snap Ring
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
1. Using SST, remove the snap ring from the transmission case.
  SST 09350-30020 (09350-07060)
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

Fig 58: Identifying Sun Gear And Thrust Bearing Race
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
1. Remove the sun gear and thrust bearing race from the transmission case.
INSPECT REAR PLANETARY SUN GEAR ASSEMBLY (See INSPECTION )
REMOVE REAR PLANETARY GEAR ASSEMBLY

Fig 59: Identifying Thrust Needle Roller Bearing, Rear Planetary Gear Assembly And Thrust Bearing Races
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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

Fig 60: Identifying 1-Way Clutch Snap Rings
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
1. Remove the 2 snap rings from the outer race.
INSPECT REAR PLANETARY GEAR ASSEMBLY (See INSPECTION )
REMOVE NO. 2 BRAKE DISC SET

Fig 61: Identifying No. 1 Plate, Discs, No. 2 Plates And Flange
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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

Fig 62: Identifying Thrust Needle Bearings, Races, Direct Clutch Assembly
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
1. Remove the 2 thrust needle bearings, 2 races, direct clutch assembly with rear planetary ring gear and output shaft from the transmission case.
REMOVE REAR PLANETARY RING GEAR

Fig 63: Removing Snap Ring
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
1. Using needle-nose pliers, detach the snap ring and disconnect the rear planetary ring gear from the output shaft.
DISCONNECT DIRECT CLUTCH ASSEMBLY

Fig 64: Identifying Thrust Needle Bearing And Thrust Bearing Race
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
1. Disconnect the direct clutch drum from the output shaft and remove the thrust needle bearing and thrust bearing race from the output shaft.
2. Remove the 3 clutch drum oil seal rings from the output shaft.
  
  Fig 65: Identifying Clutch Drum Oil Seal Rings
  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
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE NO. 2 CLUTCH DISC SET

Fig 67: Identifying Snap Ring And Flange, Discs And Plates
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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

Fig 68: Removing Snap Ring
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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)
3. Remove the No. 2 clutch balancer and direct clutch piston return spring sub-assembly from the drum.
  
  Fig 69: Identifying No. 2 Clutch Balancer And Direct Clutch Piston Return
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Remove the O-ring from the balancer.
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 )

Fig 70: Applying Compressed Air To Oil Hole Of Direct Clutch Drum
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE NO. 2 BRAKE PISTON

Fig 71: Removing Snap Ring And Brake Return Spring
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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)
3. Hold the brake piston and apply compressed air to the oil hole of the transmission case to remove the brake piston.
  
  Fig 72: Applying Compressed Air To Oil Hole Of Transmission Case
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Remove the 3 O-rings from the brake piston.
INSPECT 2ND BRAKE PISTON RETURN SPRING SUB-ASSEMBLY (See INSPECTION )
REMOVE AUTOMATIC TRANSMISSION REAR OIL SEAL

Fig 73: Removing Snap Ring
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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.
2. Using SST, remove the bearing.
  
  Fig 74: Removing Bearing
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  SST 09308-00010