Automatic Transmission Unit: Disassembly: Disassembly
- REMOVE TRANSFER ASSEMBLY
Refer to DISASSEMBLY
- REMOVE TRANSMISSION CONTROL SHAFT LEVER LH
- Remove the nut, spring washer and the transmission control shaft lever LH.
- REMOVE PARK/NEUTRAL POSITION SWITCH ASSEMBLY
- Using a screwdriver, unstake the lock washer.
- Remove the nut and lock washer.
- Remove the bolt and park/neutral position switch.
HINT:
Make sure that the manual valve lever shaft has not been rotated prior to installing the park/neutral position switch as the detent spring may become detached from the manual valve lever shaft.
- REMOVE TRANSMISSION OIL COOLER
- REMOVE TRANSMISSION REVOLUTION SENSOR
- Remove the 2 bolts and the 2 transmission revolution sensors.
- Remove the O-ring from each sensor.
- REMOVE AUTOMATIC TRANSMISSION BREATHER TUBE
- Remove the 2 bolts.
- Remove the breather tube.
- REMOVE AUTOMATIC TRANSMISSION HOUSING
- Remove the 10 bolts.
- Remove the transmission housing.
- FIX AUTOMATIC TRANSMISSION CASE SUB-ASSEMBLY
- Install the transmission case to an overhaul attachment.
- 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.
- Remove the overflow plug and the gasket.
- Remove the drain plug and the gasket.
- Remove the 20 bolts, oil pan and gasket.
- Examine particles in the pan.
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
- Remove the 6 magnets from the oil and use them 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 transaxle.
Steel (magnetic): bearing, gear and plate wear
Brass (non-magnetic): bushing wear
- Remove the 6 magnets from the oil and use them 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 transaxle.
- REMOVE VALVE BODY OIL STRAINER ASSEMBLY
- Turn over the transmission.
- Remove the 4 bolts and valve body oil strainer assembly from the valve body.
- Remove the O-ring from the valve body oil strainer assembly.
- REMOVE TRANSMISSION WIRE
- Remove the bolt and temperature sensor clamp, and disconnect the ATF temperature sensor.
- Remove the 2 bolts and disconnect the 2 clamp brackets.
- Disconnect the 9 connectors from the shift solenoid valves.
- Remove the bolt from the transmission case.
- Pull the transmission wire out of the transmission case.
- Remove the O-ring from the transmission wire.
- REMOVE TRANSMISSION VALVE BODY ASSEMBLY
- Remove the bolt, detent spring cover and detent spring.
- Remove the 20 bolts and valve body assembly.
- Separate the lever pin from the manual valve lever sub-assembly.
- REMOVE TRANSAXLE CASE GASKET
- Remove the 3 transaxle case gaskets.
- REMOVE BRAKE DRUM GASKET
- Remove the 3 brake drum gaskets.
- REMOVE CHECK BALL BODY
- Remove the check ball body and the spring.
- REMOVE C-2 ACCUMULATOR PISTON
- While blowing compressed air into the oil hole, remove the C-2 accumulator piston and the spring.
- Remove the 2 O-rings from the piston.NOTE:
Take care as the C-3 and B-3 accumulator pistons may jump out.
- REMOVE B-3 ACCUMULATOR PISTON
- While blowing compressed air into the oil hole, remove the B-3 accumulator piston and the spring.
- Remove the 2 O-rings from the piston.NOTE:
Take care as the C-3 accumulator piston may jump out.
- REMOVE C-3 ACCUMULATOR PISTON
- While blowing compressed air into the oil hole, remove the C-3 accumulator piston and the 2 springs.
- Remove the 2 O-rings from the piston.
- REMOVE B-1 ACCUMULATOR VALVE
- Remove the B-1 accumulator valve and the 2 springs.
- REMOVE PARKING LOCK PAWL BRACKET
- Remove the 3 bolts and the parking lock pawl bracket.
- REMOVE PARKING LOCK ROD SUB-ASSEMBLY
- Disconnect the parking lock rod from the manual valve lever.
- REMOVE PARKING LOCK PAWL SHAFT
- Pull out the parking lock pawl shaft from the front side, then remove the lock pawl and the parking lock pawl torsion spring.
- Remove the parking lock pawl E-ring from the parking lock pawl shaft.
- REMOVE MANUAL VALVE LEVER SUB-ASSEMBLY
- Using a hammer and a screwdriver, cut off the spacer and remove it from the shaft.
- Using a pin punch and a hammer, drive out the spring pin.Fig 31: Driving Out Spring Pin Cutting Off Spacer Driving Out Spring Pin Removing Oil Seals Identifying Transmission Case Bolts Pulling Out Oil Pump Identifying O-Ring And Oil Pump
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
HINT:
Slowly drive out the spring pin so that it does not fall into the transmission case.
- Pull the manual valve lever shaft out through the case and remove the manual valve lever.
- REMOVE MANUAL VALVE LEVER SHAFT OIL SEAL
- REMOVE OIL PUMP ASSEMBLY
- Remove the 10 bolts from the transmission case.
- Using a screwdriver with its tip wrapped with tape, pull out the oil pump.
NOTE:
Do not damage the oil pump.
- Remove the No. 1 thrust bearing race from the oil pump.
- Remove the O-ring from the oil pump.
- REMOVE CLUTCH DRUM AND INPUT SHAFT
- Remove the clutch drum and input shaft assembly from the transmission case.
- Remove the No. 2 clutch drum thrust washer, 2 thrust needle roller bearings and No. 1 thrust bearing race.
- INSPECT NO. 2 ONE WAY CLUTCH ASSEMBLY See step 20
- REMOVE NO. 2 ONE WAY CLUTCH ASSEMBLY
- Remove the No. 2 one way clutch assembly and No. 2 clutch drum thrust washer from the clutch drum and input shaft assembly.
- REMOVE NO. 3 BRAKE SNAP RING
- Using a screwdriver, remove the No. 3 brake snap ring from the transmission case.
- REMOVE NO. 3 BRAKE DISC (for 4GR-FSE)
- Remove the No. 3 brake flange, cushion plate, 3 No. 3 brake discs and 3 No. 3 brake plates from the transmission case.
- REMOVE NO. 3 BRAKE DISC (for 2GR-FSE)
- Remove the No. 3 brake flange, cushion plate, 4 No. 3 brake discs and 4 No. 3 brake plates from the transmission case.
- INSPECT NO. 3 BRAKE DISC See step 19
- REMOVE 2ND BRAKE PISTON HOLE SNAP RING
- Using SST, remove the snap ring.
- SST: 09350-30020
- 09350-07060
- SST: 09350-30020
- Using SST, remove the snap ring.
- REMOVE ONE WAY CLUTCH ASSEMBLY
- Remove the one way clutch assembly and the No. 1 planetary carrier thrust washer from the transmission case.
- REMOVE 2ND BRAKE CYLINDER
- Remove the 2nd brake cylinder from the transmission case.
- REMOVE 2ND BRAKE PISTON
- Using SST, a screwdriver and a press, remove the 2nd brake piston hole snap ring.
- SST: 09351-40010
- 09351-04060
- 09351-04070
- SST: 09351-40010
- Remove the No. 1 brake piston return spring sub-assembly.
- Hold the 2nd brake cylinder and apply compressed air (392 kPa, 4.0 kgf/cm2 , 57 psi) to the 2nd brake cylinder to remove the 2nd brake piston.
- Remove the 2 O-rings from the 2nd brake piston.
- Using SST, a screwdriver and a press, remove the 2nd brake piston hole snap ring.
- INSPECT NO. 3 BRAKE PISTON RETURN SPRING SUB-ASSEMBLY See step 18
- REMOVE FRONT PLANETARY GEAR ASSEMBLY
- Remove the front planetary gear assembly and the one way clutch inner race from the transmission case.
- Remove the thrust needle roller bearing, the No. 3 thrust bearing race and the No. 2 planetary carrier thrust washer from the front planetary gear.
- INSPECT FRONT PLANETARY GEAR ASSEMBLY See step 14
- INSPECT ONE WAY CLUTCH ASSEMBLY See step 15
- REMOVE FRONT PLANETARY RING GEAR
- Remove the front planetary ring gear from the transmission case.
- REMOVE CENTER PLANETARY RING GEAR
- Using a screwdriver, remove the front planetary ring gear shaft snap ring.
- Remove the center planetary ring gear and the front planetary ring gear flange from the front planetary ring gear.
- Remove the thrust needle roller bearing from the front planetary ring gear flange.
- REMOVE NO. 1 BRAKE DISC
- Remove the No. 1 brake flange, the 3 No. 1 brake discs and the 3 No. 1 brake plates from the transmission case.
- INSPECT NO. 1 BRAKE DISC See step 17
- REMOVE BRAKE PISTON RETURN SPRING SNAP RING
- Using a screwdriver, remove the brake piston return spring snap ring from the transmission case.
- REMOVE BRAKE PISTON RETURN SPRING SUB-ASSEMBLY
- Remove the brake piston return spring, the No. 1 brake piston and the No. 1 brake cylinder from the transmission case.
- INSPECT BRAKE PISTON RETURN SPRING SUB-ASSEMBLY See step 13
- REMOVE NO. 1 BRAKE PISTON
- Hold the No. 1 brake cylinder and apply compressed air (392 kPa, 4 kgf/cm2
, 57 psi) to the No. 1 brake cylinder to remove the No. 1 brake piston.
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
HINT:
If the piston does not pop out with compressed air, lift the piston out with needle-nose pliers.
- Remove the 2 O-rings from the No. 1 brake piston.
- Hold the No. 1 brake cylinder and apply compressed air (392 kPa, 4 kgf/cm2
, 57 psi) to the No. 1 brake cylinder to remove the No. 1 brake piston.
- REMOVE NO. 2 BRAKE DISC (for 4GR-FSE)
- Using a screwdriver, remove the No. 2 brake snap ring from the transmission case.
- Remove the 2 No. 2 brake flanges, No. 2 brake piston return spring sub-assembly, 3 No. 2 brake discs and 2 No. 2 brake plates from the transmission case.
- REMOVE NO. 2 BRAKE DISC (for 2GR-FSE)
- Using a screwdriver, remove the No. 2 brake snap ring from the transmission case.
- Remove the 2 No. 2 brake flanges, No. 2 brake piston return spring sub-assembly, 4 No. 2 brake discs and 3 No. 2 brake plates from the transmission case.
- INSPECT NO. 2 BRAKE DISC See step 9
- INSPECT NO. 2 BRAKE PISTON RETURN SPRING SUB-ASSEMBLY See step 10
- REMOVE NO. 2 BRAKE PISTON
- Hold the No. 2 brake piston and apply compressed air (392 kPa, 4 kgf/cm2
, 57 psi) to the transmission case to remove the No. 2 brake piston and the No. 2 brake bearing race cylinder.
HINT:
If the piston does not pop out with compressed air, lift the piston out with needle-nose pliers.
- Remove the piston from the cylinder.
- Remove the 2 O-rings from the No. 2 brake piston.
- Hold the No. 2 brake piston and apply compressed air (392 kPa, 4 kgf/cm2
, 57 psi) to the transmission case to remove the No. 2 brake piston and the No. 2 brake bearing race cylinder.
- REMOVE CENTER PLANETARY GEAR ASSEMBLY
- Remove the center planetary gear assembly, the planetary sun gear and the No. 4 thrust bearing race from the transmission case.
- INSPECT CENTER PLANETARY GEAR ASSEMBLY See step 8
- REMOVE INTERMEDIATE SHAFT
- Using SST, remove the snap ring from the transmission case.
- SST: 09350-30020
- 09350-07060
- SST: 09350-30020
- Remove the intermediate shaft with the No. 3 one way clutch assembly from the transmission case.
- Using SST, remove the snap ring from the transmission case.
- INSPECT NO. 3 ONE WAY CLUTCH ASSEMBLY See step 7
- REMOVE NO. 3 ONE WAY CLUTCH ASSEMBLY
- Remove the No. 3 one way clutch assembly and the one way clutch inner race from the intermediate shaft.
- REMOVE REAR PLANETARY RING GEAR FLANGE SUB-ASSEMBLY
- Remove the No. 8 thrust bearing race, the thrust needle roller bearing, the No. 7 thrust bearing race and the planetary ring gear flange from the intermediate shaft.
- INSPECT REAR PLANETARY RING GEAR FLANGE SUB-ASSEMBLY See step 6
- INSPECT INTERMEDIATE SHAFT See step 5
- REMOVE BRAKE PLATE STOPPER SPRING
- Remove the brake plate stopper spring from the transmission case.
- REMOVE NO. 4 BRAKE DISC
- Remove the rear cover sleeve, 4 No. 4 brake plates, 4 No. 4 brake discs and No. 4 brake flange from the transmission case.
- INSPECT NO. 4 BRAKE DISC See step 4
- REMOVE REAR PLANETARY GEAR ASSEMBLY
- Remove the rear planetary gear assembly from the transmission case.
- Remove the 2 thrust needle roller bearings from the rear planetary gear assembly.
- Remove the No. 9 thrust bearing race from the transmission case.
- INSPECT REAR PLANETARY GEAR ASSEMBLY See step 2
- REMOVE 1ST AND REVERSE BRAKE RETURN SPRING SUB-ASSEMBLY
- Place SST on the 1st and reverse brake return spring sub-assembly and compress the brake return spring.
- SST: 09350-30020
- 09350-07050
- SST: 09350-30020
- Using the SST, remove the 1st and reverse brake return spring shaft snap ring and the brake return spring.
- SST: 09350-30020
- 09350-07070
- SST: 09350-30020
- Place SST on the 1st and reverse brake return spring sub-assembly and compress the brake return spring.
- INSPECT 1ST AND REVERSE BRAKE RETURN SPRING SUB-ASSEMBLY See step 1
- REMOVE 1ST AND REVERSE BRAKE PISTON
- Hold the 1st and reverse brake piston and blow compressed air (392 kPa, 4 kgf/cm2
, 57 psi) into the transmission case to remove the 1st and reverse brake piston.
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
HINT:
If the piston does not pop out with compressed air, lift the piston out with needle-nose pliers.
- Remove the brake apply tube from the piston.
- Remove the O-ring from the 1st and reverse brake piston.
- Hold the 1st and reverse brake piston and blow compressed air (392 kPa, 4 kgf/cm2
, 57 psi) into the transmission case to remove the 1st and reverse brake piston.
- REMOVE BRAKE REACTION SLEEVE
- Using SST, remove the brake reaction sleeve.
- SST: 09350-30020
- 09350-07080
- SST: 09350-30020
- Remove the 2 O-rings from the brake reaction sleeve.
- Using SST, remove the brake reaction sleeve.
- REMOVE NO. 4 BRAKE PISTON
- Using SST, remove the No. 4 brake piston.
- SST: 09350-30020
- 09350-07080
- SST: 09350-30020
- Remove the 2 O-rings from the No. 4 brake piston.
- Using SST, remove the No. 4 brake piston.