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Automatic Transaxle Unit: Disassembly

  1. REMOVE PARK/NEUTRAL POSITION SWITCH ASSEMBLY 
    1. Remove the nut, washer and control shaft lever.
      Fig 1: Locating Control Shaft Lever Nut
      G05582409Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using a screwdriver, unstake the lock plate.
    3. Remove the nut and lock plate.
      Fig 2: Removing Lock Plate Nut
      G05582410Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Remove the 2 bolts and pull out the switch.
  2. REMOVE BREATHER PLUG HOSE 
    Fig 3: Locating Park/Neutral Position Switch Bolt
    G05582411Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  3. REMOVE OIL COOLER OUTLET TUBE UNION 
    1. Remove the union.
    2. Remove the O-ring from the union.
    Fig 4: Identifying Oil Cooler Outlet Tube Union And O-Ring
    G05582412Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  4. REMOVE OIL COOLER INLET TUBE UNION 
    1. Remove the union.
    2. Remove the O-ring from the union.
    Fig 5: Identifying Oil Cooler Inlet Tube Union And O-Ring
    G05582632Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  5. REMOVE SPEED SENSOR 
    1. Remove the 2 bolts and 2 speed sensors from the transaxle.
    2. Remove the 2 O-rings from the sensors.
    Fig 6: Identifying Speed Sensor Bolts And O-Rings
    G05582414Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  6. REMOVE NO. 1 TRANSAXLE CASE PLUG 
    1. Remove the 4 plugs from the transaxle case.
    2. Remove the 4 O-rings from the 4 plugs.
    Fig 7: Identifying Transaxle Case Plugs And O-Rings
    G05388262Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  7. SECURE AUTOMATIC TRANSAXLE ASSEMBLY 
    1. Secure the transaxle assembly onto wooden blocks.
    Fig 8: Securing Transaxle Assembly Onto Wooden Blocks
    G05582416Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  8. REMOVE AUTOMATIC TRANSAXLE OIL PAN SUB-ASSEMBLY 
    1. Remove the 18 bolts.
    2. Remove the oil pan and 3 magnets.
    3. Remove the gasket from the oil pan.
  9. INSPECT TRANSMISSION OIL CLEANER MAGNET  (See INSPECTION )
    Fig 9: Locating Automatic Transaxle Oil Pan Sub-Assembly Bolts
    G05388265Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  10. REMOVE VALVE BODY OIL STRAINER ASSEMBLY 
    1. Remove the 3 bolts and oil strainer.
      Fig 10: Locating Oil Strainer Bolts
      G05582418Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the O-ring from the oil strainer.
    Fig 11: Locating Oil Strainer O-Ring
    G05388268Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  11. REMOVE TRANSMISSION WIRE 
    1. Disconnect the 5 shift solenoid valve connectors.
    2. Remove the bolt, lock plate and ATF temperature sensor.
      Fig 12: Identifying Lock Plate
      G05388269Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Remove the bolt and transmission wire.
      Fig 13: Locating Transmission Wire Bolt
      G05388270Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Remove the O-ring from the transmission wire.
    Fig 14: Locating Transmission Wire O-Ring
    G05582422Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  12. REMOVE TRANSMISSION VALVE BODY ASSEMBLY 
    1. Support the valve body and remove the 17 bolts and valve body.
    Fig 15: Locating Transmission Valve Body Bolts
    G06043159Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  13. REMOVE NO. 1 GOVERNOR APPLY GASKET 
    1. Remove the governor apply gasket from the transaxle case.
    Fig 16: Locating No. 1 Governor Gasket
    G05388273Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  14. REMOVE TRANSAXLE CASE 2ND BRAKE GASKET 
    1. Remove the 2nd brake gasket from the transaxle case.
    Fig 17: Locating Transaxle Case 2nd Brake Gasket
    G05388274Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  15. REMOVE BRAKE DRUM GASKET 
    1. Remove the brake drum gasket from the transaxle case.
    Fig 18: Locating Brake Drum Gasket
    G05388275Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  16. REMOVE CHECK BALL BODY 
    1. Remove the check ball body and spring from the transaxle.
    Fig 19: Identifying Check Ball Body And Spring
    G05388276Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  17. REMOVE C-3 ACCUMULATOR PISTON 
    1. Remove the spring from the C-3 accumulator piston.
      Fig 20: Identifying C-3 Accumulator Spring
      G05388277Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    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 by hand using a piece of cloth.
      • Do not spatter ATF when applying compressed air.
      Fig 21: Applying Compressed Air To Oil Hole
      G05388282Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Remove the O-ring from the C-3 accumulator piston.
    Fig 22: Locating C-3 Accumulator Piston O-ring
    G05388279Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  18. REMOVE C-1 ACCUMULATOR PISTON 
    1. Apply compressed air (392 kPa, 4.0 kgf/cm2 , 57 psi) to the oil hole and remove the C-1 accumulator piston and spring.
      NOTE:
      • Applying compressed air may cause the piston to jump out. When removing the piston, hold it by hand using a piece of cloth.
      • Do not spatter ATF when applying compressed air.
      Fig 23: Removing C-1 Accumulator Piston And Spring
      G05388280Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the 2 O-rings from the C-1 accumulator piston.
    Fig 24: Locating C-1 Accumulator Piston O-ring
    G05388281Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  19. REMOVE B-3 ACCUMULATOR PISTON 
    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 by hand using a piece of cloth.
      • Do not spatter ATF when applying compressed air.
      Fig 25: Applying Compressed Air To Oil Hole
      G05388282Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the O-ring from the B-3 accumulator piston.
    Fig 26: Locating B-3 Accumulator Piston O-ring
    G05388283Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  20. REMOVE MANUAL DETENT SPRING SUB-ASSEMBLY 
    1. Remove the 2 bolts, manual detent spring and cover.
    Fig 27: Locating Manual Detent Spring Subassembly Bolts
    G05388284Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  21. REMOVE PARKING LOCK PAWL BRACKET 
    1. Remove the 2 bolts and parking lock pawl bracket.
    Fig 28: Locating Parking Lock Pawl Bracket Bolts
    G05388285Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  22. REMOVE MANUAL VALVE LEVER SHAFT RETAINER SPRING 
    1. Using needle-nose pliers, remove the retainer spring.
    Fig 29: Removing Manual Valve Lever Shaft Retainer Spring
    G05388286Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  23. REMOVE MANUAL VALVE LEVER SUB-ASSEMBLY 
    1. Using a chisel and hammer, unstake and remove the spacer.
      Fig 30: Removing Spacer
      G05582438Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using a pin punch and hammer, tap out the pin.

      HINT:

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

      Fig 31: Tapping Pin Into Transaxle
      G05388288Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Remove the manual valve lever shaft and manual valve lever.
    Fig 32: Removing Manual Valve Lever Shaft And Manual Valve Lever
    G05388289Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  24. REMOVE PARKING LOCK ROD SUB-ASSEMBLY 
    1. Remove the parking lock rod from the manual valve lever.
    Fig 33: Removing Parking Lock Rod Sub-Assembly
    G05388290Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  25. REMOVE MANUAL VALVE LEVER SHAFT OIL SEAL 
    1. Using a screwdriver, pry out the oil seal from the transaxle.
  26. SECURE AUTOMATIC TRANSAXLE ASSEMBLY 
    1. Secure the automatic transaxle assembly with the oil pump side facing up.
  27. INSPECT INPUT SHAFT END PLAY  (See INSPECTION )
    Fig 34: Prying Oil Seal From Transaxle
    G05388291Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  28. REMOVE NO. 1 TRANSAXLE CASE PLUG 
    1. Remove the 2 plugs.
    2. Remove the 2 O-rings from the 2 plugs.
    Fig 35: Identifying No. 1 Transaxle Case Plug And O-Rings
    G05388263Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  29. REMOVE TRANSAXLE HOUSING 
    1. Remove the 18 bolts.
    2. Tap on the circumference of the transaxle housing with a plastic-faced 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
    G06043338Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  30. REMOVE OIL PUMP ASSEMBLY 
    1. Remove the 7 bolts and oil pump from the transaxle.
    Fig 37: Locating Oil Pump Assembly Bolts
    G05415811Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  31. REMOVE THRUST NEEDLE ROLLER BEARING 
    1. Remove the thrust needle roller bearing from the underdrive planetary gear.
    Fig 38: Identifying Thrust Needle Roller Bearing
    G05388296Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  32. REMOVE NO. 2 THRUST BEARING UNDERDRIVE RACE 
    1. Remove the thrust bearing underdrive race from the underdrive planetary gear.
    Fig 39: Identifying No. 2 Thrust Bearing Underdrive Race
    G05388297Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  33. REMOVE DIFFERENTIAL GEAR ASSEMBLY 
    1. Remove the differential gear from the transaxle.
    Fig 40: Removing/Installing Differential Gear Assembly
    G05388298Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  34. REMOVE OVERDRIVE BRAKE GASKET 
    1. Remove the 2 overdrive brake gaskets from the transaxle.
    Fig 41: Removing/Installing Overdrive Brake Gaskets
    G05388299Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  35. REMOVE FORWARD CLUTCH ASSEMBLY 
    1. Remove the forward clutch from the transaxle.
      Fig 42: Identifying Forward Clutch Assembly
      G05388300Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the thrust bearing from the forward clutch.
  36. INSPECT PACK CLEARANCE OF FORWARD CLUTCH  (See INSPECTION )
    Fig 43: Identifying Thrust Bearing
    G05388301Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  37. REMOVE FORWARD MULTIPLE DISC CLUTCH DISC 
    1. Using a screwdriver, remove the snap ring.
      Fig 44: Removing Snap Ring
      G05388525Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the flange, 5 discs and 5 plates from the input shaft.
  38. INSPECT FORWARD MULTIPLE DISC CLUTCH DISC  (See INSPECTION )
    Fig 45: Identifying Flange, Discs And Plates
    G05388526Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  39. REMOVE FORWARD CLUTCH RETURN SPRING SUB-ASSEMBLY 
    1. Place SST on the spring retainer and compress the return spring with a press.

      SST 09350-32014 (09351 -32070) 

    2. Using a snap ring expander, remove the snap ring.
      Fig 46: Removing Snap Ring
      G05246345Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Remove the forward clutch return spring sub-assembly.
  40. INSPECT FORWARD CLUTCH RETURN SPRING SUB-ASSEMBLY  (See INSPECTION )
    Fig 47: Identifying Clutch Return Spring Sub-Assembly
    G05246346Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  41. REMOVE FORWARD CLUTCH PISTON SUB-ASSEMBLY 
    1. Place the forward clutch drum onto the oil pump.
    2. Holding the forward clutch piston by hand, apply compressed air (392 kPa, 4.0 kgf/cm2 , 57 psi) to the oil pump to remove the forward clutch piston sub-assembly.
    Fig 48: Applying Compressed Air To Oil Pump
    G05388529Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

    HINT:

    When the piston is slanted and cannot be removed, remove it by pushing down the protruding side and applying compressed air again, or using needlenose pliers (with its tips wrapped in tape).

  42. INSPECT FORWARD CLUTCH PISTON SUB-ASSEMBLY  (See INSPECTION )
  43. REMOVE INPUT SHAFT OIL SEAL RING 
    1. Remove the input shaft oil seal ring from the forward clutch drum.
    Fig 49: Removing Input Shaft Oil Seal Ring
    G05388531Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  44. REMOVE MULTIPLE DISC CLUTCH HUB 
    1. Remove the thrust needle roller bearing, multiple clutch hub, needle roller bearing and bearing race from the transaxle.
  45. INSPECT MULTIPLE DISC CLUTCH HUB  (See INSPECTION )
    Fig 50: Identifying Multiple Disc Clutch Hub
    G05388302Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  46. REMOVE UNDERDRIVE PLANETARY GEAR ASSEMBLY 
    1. Remove the bolt and parking pawl shaft clamp.
      Fig 51: Identifying Bolt And Parking Pawl Shaft Clamp
      G05388303Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the parking lock pawl shaft.
      Fig 52: Removing Parking Lock Pawl Shaft
      G05582454Courtesy 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 53: Pushing Parking Lock Pawl
      G05582455Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Remove the underdrive planetary gear from the transaxle.
      NOTE: Be careful not to drop the underdrive planetary gear assembly.
      Fig 54: Removing/Installing Underdrive Planetary Gear
      G05388306Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Remove the spring, pawl pin and parking lock pawl.
  47. INSPECT UNDERDRIVE PLANETARY GEAR PRELOAD  (See INSPECTION )
    Fig 55: Removing Parking Lock Pawl
    G05582457Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  48. REMOVE UNDERDRIVE INPUT SHAFT NUT 
    1. Using SST, secure the underdrive planetary gear.

      SST 09387-00050 

      Fig 56: Securing Underdrive Planetary Gear Using SST 09387-00050
      G05582711Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using SST, loosen the staked part of the nut.

      SST 09930-00010 (09931-00010, 09931-00020) 

      Fig 57: Loosening Staked Part Of Nut
      G04976395Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Clamp the underdrive planetary gear in a soft jaw vise.
      NOTE: Be careful not to damage the differential drive pinion.
      Fig 58: Clamping Underdrive Planetary Gear In Soft Jaw Vise
      G05582713Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Using a socket wrench, remove the lock nut.
    Fig 59: Removing Lock Nut
    G05582714Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  49. REMOVE CYLINDRICAL ROLLER BEARING INNER RACE 
    1. Using SST, remove the cylindrical roller bearing inner race.

      SST 09950-00020, 09950-00030, 09950-60010 (09951-00340), 09950-40011 (09957-04010) 

      Fig 60: Removing Cylindrical Roller Bearing Inner Race
      G06043362Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  50. REMOVE UNDERDRIVE PLANETARY GEAR ASSEMBLY 
    1. Using SST and a press, remove the differential drive pinion, parking lock gear, counter driven gear with underdrive planetary ring gear, and angular ball bearing.

      SST 09387-00050 

    2. Clamp the underdrive planetary gear in a soft jaw vise.
      Fig 61: Securing Underdrive Planetary Gear Assembly Using SST 09387-00050
      G05246388Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Using SST, remove the rear angular ball bearing from the underdrive planetary gear.

      SST 09950-00020, 09950-00030, 09950-60010 (09951-00320), 09950-40011 (09957-04010) 

      Fig 62: Removing Rear Angular Ball Bearing
      G06043364Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  51. REMOVE UNDERDRIVE PLANETARY RING GEAR 
    1. Using snap ring pliers, remove the snap ring.
      Fig 63: Removing Snap Ring
      G05582718Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the underdrive planetary ring gear from the counter driven gear.
    Fig 64: Identifying Underdrive Planetary Ring Gear And Counter Driven Gear
    G04976402Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  52. REMOVE UNDERDRIVE CLUTCH ASSEMBLY 
    1. Remove the underdrive clutch assembly, thrust bearing and bearing race from the transaxle.
  53. INSPECT PACK CLEARANCE OF UNDERDRIVE CLUTCH  (See INSPECTION )
    Fig 65: Identifying Underdrive Clutch Assembly
    G05388308Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  54. REMOVE NO. 1 UNDERDRIVE CLUTCH DISC 
    1. Using a screwdriver, pry out the underdrive clutch flange snap ring.
      Fig 66: Removing No. 1 Underdrive Clutch Disc
      G05582736Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the flange, 3 discs and 3 plates from the underdrive clutch drum.
  55. INSPECT NO. 1 UNDERDRIVE CLUTCH DISC  (See INSPECTION )
  56. INSPECT UNDERDRIVE CLUTCH DRUM SUB-ASSEMBLY  (See INSPECTION )
    Fig 67: Identifying Flange, Discs And Plates
    G05246409Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  57. REMOVE UNDERDRIVE CLUTCH DRUM O-RING 
    1. Remove the underdrive clutch drum O-ring from the underdrive clutch drum.
    Fig 68: Identifying Underdrive Clutch Drum O-Ring
    G05388596Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  58. REMOVE UNDERDRIVE CLUTCH PISTON SET 
    1. Place SST on the clutch balancer and compress the spring with a press.

      SST 09350-32014 (09351-32070) 

    2. Using a snap ring expander, remove the snap ring.
      NOTE:
      • Stop the press when the spring seat is lowered 1 to 2 mm (0.0394 to 0.0787 in.) from the snap ring groove. This prevents the spring seat from being deformed.
      • Do not expand the snap ring excessively.
      Fig 69: Removing Underdrive Clutch Piston Set
      G05388592Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Remove the clutch balancer from the underdrive clutch drum.
      Fig 70: Removing/Installing Clutch Balancer And Underdrive Clutch Drum
      G05582740Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Remove the piston return spring from the underdrive clutch drum.
      Fig 71: Removing Piston Return Spring
      G05582749Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Install the underdrive clutch to the transaxle.
      NOTE: Be careful not to damage the oil seal rings.
    6. Holding the underdrive clutch piston by hand, apply compressed air (392 kPa, 4.0 kgf/cm2 , 57 psi) to the transaxle case to remove the underdrive clutch piston.
    Fig 72: Installing Underdrive Clutch To Transaxle
    G05582742Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  59. INSPECT UNDERDRIVE CLUTCH RETURN SPRING SUB-ASSEMBLY  (See INSPECTION )
  60. REMOVE UNDERDRIVE ONE-WAY CLUTCH ASSEMBLY 
    1. Using a screwdriver, pry out the snap ring from the transaxle.
      Fig 73: Removing/Installing Snap Ring On Transaxle
      G05388309Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the one-way clutch from the transaxle.
      Fig 74: Identifying One-Way Clutch On Transaxle
      G05388310Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Remove the outer race retainer from the one-way clutch.
    Fig 75: Identifying Outer Race Retainer
    G05388423Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  61. REMOVE NO. 2 UNDERDRIVE CLUTCH DISC 
    1. Using a screwdriver, pry out the snap ring.
      Fig 76: Removing Snap Ring
      G05388312Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the flange, 3 discs and 3 plates from the transaxle.
  62. INSPECT NO. 2 UNDERDRIVE CLUTCH DISC  (See INSPECTION )
    Fig 77: Identifying Flange, Discs And Plates
    G05388313Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  63. REMOVE UNDERDRIVE BRAKE RETURN SPRING SUB-ASSEMBLY 
    1. Using SST, a snap ring expander and press, remove the snap ring and underdrive brake return spring.

      SST 09387-00020 

  64. INSPECT UNDERDRIVE BRAKE RETURN SPRING SUB-ASSEMBLY  (See INSPECTION )
    Fig 78: Removing Snap Ring And Underdrive Brake Return Spring Sub-Assembly
    G05246137Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  65. REMOVE NO. 1 TRANSAXLE CASE PLUG 
    1. Remove the 2 plugs from the transaxle rear cover.
    2. Remove the 2 O-rings from the 2 plugs.
    Fig 79: Identifying No. 1 Transaxle Case Plugs And O-Rings
    G05388264Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  66. REMOVE TRANSAXLE REAR COVER SUB-ASSEMBLY 
    1. Remove the 11 bolts.
      Fig 80: Identifying Transaxle Rear Cover Sub-Assembly Bolts
      G05388317Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Tap in the circumference of the rear cover with a plastic-faced hammer to remove the transaxle rear cover from the transaxle.
    3. Remove the 2 oil seal rings from the transaxle rear cover.
      Fig 81: Identifying Oil Seal Rings
      G05582467Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Using a T30 "TORX" socket wrench, remove the 2 screws and transaxle rear cover plate.
      Fig 82: Identifying Transaxle Rear Cover Plate Screws
      G05388319Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Using SST, remove the needle-roller bearing from the transaxle rear cover.

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

      Fig 83: Removing Needle-Roller Bearing From Transaxle Rear Cover
      G05246143Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  67. REMOVE BRAKE APPLY TUBE 
    1. Remove the bolt, clamp and brake apply tube.
    2. Remove the brake apply tube from the clamp.
  68. REMOVE FRONT CLUTCH APPLY TUBE 
    1. Remove the front clutch apply tube from the clamp.
    Fig 84: Identifying Clutch Apply Tube
    G05388323Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  69. REMOVE NO. 1 GOVERNOR APPLY GASKET 
    1. Using a screwdriver, remove the 2 apply gaskets.
    Fig 85: Locating No. 1 Governor Gasket
    G05246145Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  70. REMOVE DIRECT CLUTCH ASSEMBLY 
    1. Remove the thrust bearing and direct clutch from the transaxle.
      Fig 86: Identifying Thrust Bearing And Direct Clutch Assembly
      G05388325Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the bearing race from the direct clutch.
  71. INSPECT PACK CLEARANCE OF DIRECT CLUTCH  (See INSPECTION )
    Fig 87: Identifying Bearing Race And Direct Clutch
    G05388400Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  72. REMOVE DIRECT MULTIPLE DISC CLUTCH DISC 
    1. Using a screwdriver, pry out the snap ring from the direct clutch drum.
      Fig 88: Removing/Installing Snap Ring
      G05388547Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the flange, 3 discs and 3 plates from the direct clutch drum.
  73. INSPECT DIRECT MULTIPLE DISC CLUTCH DISC  (See INSPECTION )
    Fig 89: Identifying Flange, Discs And Plates
    G05388548Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  74. REMOVE DIRECT CLUTCH RETURN SPRING SUB-ASSEMBLY 
    1. Place SST on the clutch balancer and compress the spring with a press.

      SST 09387-00020 

    2. Using a snap ring expander, remove the snap ring from the direct clutch drum.
      Fig 90: Removing Snap Ring From Direct Clutch Drum
      G05246368Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:
      • Stop the press when the spring seat is lowered 1 to 2 mm (0.0394 to 0.0787 in.) from the snap ring groove. This prevents the spring seat from being deformed.
      • Do not expand the snap ring excessively.
    3. Remove the clutch balancer from the direct clutch drum.
      Fig 91: Removing/Installing Clutch Balancer
      G05388550Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Remove the return spring from the direct clutch drum.
      Fig 92: Removing Return Spring
      G05388551Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Install the direct clutch drum on the transaxle rear cover.
    6. Holding the direct clutch piston by hand, apply compressed air (392 kPa, 4.0 kgf*cm2 , 57 psi) to the transaxle rear cover to remove the direct clutch piston.
  75. INSPECT DIRECT CLUTCH RETURN SPRING SUB-ASSEMBLY  (See INSPECTION )
    Fig 93: Removing Direct Clutch Piston
    G05388552Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  76. REMOVE REAR PLANETARY SUN GEAR ASSEMBLY 
    1. Remove the rear planetary sun gear from the transaxle.
      Fig 94: Identifying Rear Planetary Sun Gear Assembly
      G05388327Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the thrust bearing from the rear planetary sun gear.
      Fig 95: Identifying Thrust Bearing And Rear Planetary Sun Gear
      G05388328Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Remove the No. 2 washer from the rear planetary sun gear.
    Fig 96: Identifying No. 2 Washer On Rear Planetary Sun Gear
    G05388394Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  77. REMOVE ONE-WAY CLUTCH ASSEMBLY 
    1. Remove the one-way clutch and thrust bearing from the transaxle.
      Fig 97: Identifying One-Way Clutch And Thrust Bearing
      G05388393Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the inner race from the one-way clutch.
    Fig 98: Identifying Inner Race And One-Way Clutch
    G05388331Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  78. REMOVE ONE-WAY CLUTCH OUTER SLEEVE 
    Fig 99: Identifying One-Way Clutch Outer Sleeve
    G05388332Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  79. REMOVE 2ND BRAKE CLUTCH DISC 
    1. Using a screwdriver, remove the snap ring.
    2. Remove the flange, 3 discs and 3 plates from the transaxle.
  80. INSPECT 2ND BRAKE CLUTCH DISC  (See INSPECTION )
    Fig 100: Identifying Flange, Discs And Plates
    G05388333Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  81. REMOVE 2ND BRAKE PISTON ASSEMBLY 
    1. Using a screwdriver, remove the snap ring.
      Fig 101: Removing Snap Ring
      G05388334Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the 2nd brake piston from the transaxle.
    Fig 102: Removing 2nd Brake Piston Of Transaxle
    G05388335Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  82. REMOVE 2ND BRAKE PISTON RETURN SPRING SUB-ASSEMBLY 
    1. Using SST and a press, remove the snap ring from the 2nd brake piston.

      SST 09387-00060 

    2. Using a screwdriver, pry out the snap ring.
      Fig 103: Prying Snap Ring
      G04831489Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Remove the piston return spring.
  83. INSPECT 2ND BRAKE PISTON RETURN SPRING SUB-ASSEMBLY  (See INSPECTION )
    Fig 104: Identifying Piston Return Spring
    G05582661Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  84. REMOVE 2ND BRAKE PISTON 
    1. Hold the 2nd brake piston and apply compressed air (392 kPa, 4.0 kgf/cm2 , 57 psi) to the 2nd brake cylinder to remove the 2nd brake piston.
    Fig 105: Removing 2nd Brake Piston
    G05582662Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  85. REMOVE 2ND BRAKE PISTON O-RING 
    1. Remove the 2 O-rings from the 2nd brake piston.
    Fig 106: Identifying 2nd Brake Piston O-Ring
    G05582663Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  86. REMOVE REAR PLANETARY GEAR ASSEMBLY 
    1. Using a screwdriver, pry out the snap ring.
      Fig 107: Prying Snap Ring
      G05388337Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the rear planetary gear from the transaxle.
      Fig 108: Identifying Rear Planetary Gear On Transaxle
      G05388338Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Remove the No. 1 washer from the rear planetary gear.
      Fig 109: Identifying No. 1 Washer On Rear Planetary Gear
      G05388339Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Remove the bearing race from the rear planetary gear.
    Fig 110: Identifying Bearing Race On Rear Planetary Gear
    G05388340Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  87. REMOVE INPUT SUN GEAR 
    1. Remove the 2 thrust bearings, bearing race and input sun gear from the transaxle.
      Fig 111: Identifying Thrust Bearings, Bearing Race And Input Sun Gear
      G05388341Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  88. REMOVE FRONT PLANETARY GEAR ASSEMBLY 
    1. Using a chisel and a hammer, unstake the lock washer.
      NOTE: Push down all of the washer claws. Otherwise SST cannot be fully pressed against and loosen the nut.
      Fig 112: Unstaking Lock Washer
      G05388342Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using SST, remove the nut.

      SST 09387-00030,09387-00080 

      Fig 113: Removing Front Planetary Gear Nut
      G04976178Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Using SST and a press, remove the front planetary gear from the counter drive gear.

      SST 09950-60010 (09951 -00450) 

      Fig 114: Removing Front Planetary Gear Of Counter Drive Gear
      G05246164Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Remove the front planetary gear from the brake hub.
    Fig 115: Removing Front Planetary Gear From Brake Hub
    G05388345Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  89. REMOVE FRONT PLANETARY RING GEAR 
    1. Using a screwdriver, remove the snap ring and front planetary ring gear from the brake hub.
    Fig 116: Identifying Front Planetary Ring Gear
    G05388346Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  90. REMOVE 1ST AND REVERSE BRAKE CLUTCH DISC 
    1. Remove the flange, 5 discs and 5 plates from the transaxle case.
  91. INSPECT 1ST AND REVERSE BRAKE CLUTCH DISC  (See INSPECTION )
    Fig 117: Identifying Flange, Discs And Plates On Transaxle Case
    G05388336Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  92. REMOVE 1ST AND REVERSE BRAKE RETURN SPRING SUB-ASSEMBLY 
    1. Using SST, a press and snap ring expander, remove the snap ring and 1st and reverse brake return spring sub-assembly.
      Fig 118: Removing/Installing Snap Ring With 1st And Reverse Brake Return Spring Sub-Assembly
      G04976182Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      SST 09387-00070 

      NOTE:
      • Stop the press when the spring seat is lowered 1 to 2 mm (0.0394 to 0.0787 in.) from the snap ring groove. This prevents the spring seat from being deformed.
      • Do not expand the snap ring excessively.
  93. INSPECT 1ST AND REVERSE BRAKE RETURN SPRING SUB-ASSEMBLY  (See INSPECTION )
  94. REMOVE 1ST AND REVERSE BRAKE PISTON 
    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 by hand using a piece of cloth.
      • Do not spatter ATF when applying compressed air.
      Fig 119: Applying Compressed Air To Transaxle Case
      G05388349Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the 2 O-rings from the 1st and reverse brake piston.
    Fig 120: Locating O-rings
    G05388350Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  95. REMOVE COUNTER DRIVE GEAR 
    1. Using SST and a press, remove the counter drive gear from the transaxle case.

      SST 09950-60010 (09951-00580), 09950-70010 (09951-07100) 

      Fig 121: Removing Counter Drive Gear
      G05246171Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. As shown in the illustration, tighten 2 service bolts evenly and make a clearance of approximately 20.0 mm (0.787 in.) between the counter drive gear and the inner race.
      Fig 122: Tightening Service Bolts
      G04976186Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Using SST, remove the tapered roller bearing.

      SST 09950-60010 (09951-00580), 09950-00020, 09950-00030 

      Fig 123: Removing Tapered Roller Bearing
      G05246173Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Using a brass bar and a hammer, tap out the 2 bearing outer races.
    Fig 124: Tapping Bearing Outer Races
    G05388354Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  96. REMOVE COUNTER DRIVE GEAR HOLE SNAP RING 
    1. Using a screwdriver, pry out the snap ring from the transaxle.
  97. REMOVE NO. 2 BREATHER PLUG 
    Fig 125: Prying Snap Ring From Transaxle
    G05388355Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  98. REMOVE UNDERDRIVE BRAKE PISTON 
    1. Apply compressed air (392 kPa, 4.0 kgf/cm2 , 57 psi) to the transaxle case to remove the underdrive brake piston.
      NOTE:
      • Applying compressed air may cause the piston to jump out. When removing the piston, hold it by hand using a piece of cloth.
      • Do not spatter ATF when applying compressed air.
      Fig 126: Applying Compressed Air To Transaxle Case
      G05246176Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the 2 O-rings from the underdrive brake piston.
      Fig 127: Locating O-rings
      G05388322Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Using SST, remove the needle-roller bearing from the transaxle.

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

      Fig 128: Removing Needle-Roller Bearing
      G05246178Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  99. REMOVE UNDERDRIVE CLUTCH DRUM OIL SEAL RING 
    1. Remove the 2 oil seal rings from the transaxle.
    Fig 129: Identifying Underdrive Clutch Drum Oil Seal Rings
    G05388316Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  100. REMOVE UNDERDRIVE CYLINDRICAL ROLLER BEARING 
    1. Using SST, remove the cylindrical roller bearing from the transaxle.

      SST 09514-35011 

      Fig 130: Removing Underdrive Cylindrical Roller Bearing
      G05240709Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  101. REMOVE UNDERDRIVE OUTPUT SHAFT OIL SEAL RING 
    1. Remove the oil seal ring from the transaxle housing.
    Fig 131: Identifying Oil Seal Ring
    G05388294Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  102. REMOVE DIFFERENTIAL GEAR LUBE APPLY TUBE 
    1. Remove the bolt, clamp and apply tube from the transaxle.
    Fig 132: Identifying Transaxle Bolt And Clamp
    G05388356Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002