AUTOMATIC TRANSMISSION UNIT DISASSEMBLY


  1. REMOVE DRAIN (ATM) PLUG SUB-ASSEMBLY

  2. REMOVE BREATHER PLUG HOSE

  3. REMOVE TRANSMISSION CONTROL SHAFT LEVER LH


    1. Remove the nut, the washer and the control shaft lever.

  4. REMOVE TRANSMISSION CASE PLUG ASSEMBLY


    1. A01BH51

      Remove the bolt and pull out the plug.

    2. Remove the O-ring from the plug.

  5. REMOVE PARK/NEUTRAL POSITION SWITCH ASSEMBLY


    1. A01BHXJE01

      Using a screwdriver, pull up the lock washer.

    2. Remove the nut and lock washer.

    3. A01BEY3

      Remove the bolt and the park/neutral position switch.

      Tech Tips

      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.

  6. REMOVE OIL COOLER TUBE UNION


    1. A01BGFU

      Remove the 2 oil cooler tube unions.

    2. Remove the O-rings from the oil cooler tube unions.

  7. REMOVE TEMPERATURE SENSOR


    1. A01BHRD

      Remove the temperature sensor.

    2. Remove the O-ring from the sensor.

  8. REMOVE SPEED SENSOR


    1. A01BDQ3

      Remove the bolt and speed sensor.

    2. Remove the O-ring from the sensor.

  9. REMOVE TRANSMISSION REVOLUTION SENSOR


    1. A01BHP0

      Remove the bolt and the transmission revolution sensor.

    2. Remove the O-ring from the sensor.

  10. REMOVE EXTENSION HOUSING SUB-ASSEMBLY


    1. A01BEGH

      Remove the 6 bolts.

    2. Remove the extension housing and the gasket.

  11. REMOVE EXTENSION HOUSING BUSH APPLY TUBE GASKET


    1. A01BDIAE01

      Remove the bush apply tube gasket.

  12. REMOVE EXTENSION HOUSING BUSH APPLY TUBE


    1. A01BDIAE03

      Remove the bush apply tube.

  13. REMOVE AUTOMATIC TRANSMISSION EXTENSION HOUSING OIL SEAL


    1. A01BGPX

      Using a screwdriver, remove the extension housing oil seal.

  14. REMOVE EXTENSION HOUSING DUST DEFLECTOR


    1. A01BBVN

      Mount the extension housing in a soft jaw vise.

    2. Using a screwdriver and a hammer, remove the extension housing dust deflector.

  15. INSPECT EXTENSION HOUSING SUB-ASSEMBLY


    1. A01BATM

      Using a cylinder gauge, measure the inside diameter of the extension housing bushing.

      Maximum inside diameter
      40.02 mm (1.5756 in.)

      If the inside diameter is greater than the maximum, replace the extension housing.

  16. REMOVE SENSOR ROTOR


    1. A01BE6SE01

      Using a snap ring expander, remove the rear side snap ring.

    2. Remove the sensor rotor and the key.

    3. Using a snap ring expander, remove the front side snap ring.

  17. REMOVE AUTOMATIC TRANSMISSION HOUSING


    1. A01BHUQ

      Remove the 6 bolts.

    2. Remove the transmission housing.

  18. FIX AUTOMATIC TRANSMISSION CASE SUB-ASSEMBLY


    1. A01BF2T

      Install the transmission case on the overhaul attachment.

  19. REMOVE AUTOMATIC TRANSMISSION OIL PAN SUB-ASSEMBLY


    1. A01BA82

      Remove the 19 bolts.

      Note

      Do not turn the transmission over as this will contaminate the valve body with any foreign matter at the bottom of the pan.

    2. A01BCOUE04

      Insert oil pan seal cutter between the transmission case and the oil pan. Cut through the seal and remove the oil pan.

      Note

      Be careful not to damage the oil pan and flange.

    3. Remove the pan by lifting the transmission case.

  20. INSPECT AUTOMATIC TRANSMISSION OIL PAN SUB-ASSEMBLY


    1. A01BDW0E03

      Remove any FIPG material and be careful not to drop oil on the contacting surfaces of the transmission case and the oil pan.

    2. Apply FIPG to the oil pan.

      FIPG
      Toyota Genuine Seal Packing 1281, Three Bond 1281 or equivalent

    3. Install the oil pan with the 19 bolts.

      Torque:
      7.4 N*m  { 75 kgf*cm, 65 in.*lbf }

  21. REMOVE VALVE BODY OIL STRAINER ASSEMBLY


    1. A01BCEM

      Remove the 4 bolts and oil strainer case.

  22. REMOVE TRANSMISSION WIRE


    1. A01BESI

      Disconnect the 4 connectors from each shift solenoid valve.

    2. A01BBEX

      Remove the bolt.

    3. Pull out the solenoid wiring from the transmission case.

    4. Remove the O-rings from the solenoid wiring.

  23. REMOVE TRANSMISSION VALVE BODY ASSEMBLY


    1. A01BDN0

      Remove the 20 bolts.

  24. REMOVE CHECK BALL BODY


    1. A01BGN3

      Remove the check ball body and the spring.

  25. REMOVE B-2 ACCUMULATOR PISTON


    1. A01BI41

      Applying compressed air to the oil hole, remove the B2 accumulator piston and the spring.

    2. Remove the O-rings from the piston.

  26. REMOVE C-2 ACCUMULATOR PISTON


    1. A01BI41

      Applying compressed air to the oil hole, remove the C2 accumulator piston and the springs.

    2. Remove the O-rings from the piston.

  27. REMOVE B-0 ACCUMULATOR PISTON


    1. A01BCWX

      Applying compressed air to the oil hole, remove the B0 accumulator piston and the spring.

    2. Remove the O-rings from the piston.

  28. REMOVE C-0 ACCUMULATOR PISTON


    1. A01BFOI

      Applying compressed air to the oil hole, remove the C0 accumulator piston and the springs.

    2. Remove the O-ring from the piston.

  29. REMOVE PARKING LOCK PAWL BRACKET


    1. A01BEL2

      Remove the 3 bolts and the parking lock pawl bracket.

  30. REMOVE PARKING LOCK ROD SUB-ASSEMBLY


    1. A01BBYT

      Disconnect the parking lock rod from the manual valve lever.

  31. REMOVE PARKING LOCK PAWL SHAFT


    1. A01BFZDE01

      Pull out the parking lock pawl shaft from the front side, then remove the lock pawl and the spring.

    2. Remove the E-ring from the shaft.

  32. REMOVE MANUAL VALVE LEVER SUB-ASSEMBLY


    1. A01BA9TE01

      Using a hammer and a screwdriver, cut off the spacer and remove it from the shaft.

    2. A01BB38

      Using a pin punch and a hammer, drive out the pin.

      Tech Tips

      Slowly drive out the pin so that it does not fall into the transmission case.

    3. Pull out the manual valve lever shaft through the case, and remove the manual valve lever.

  33. REMOVE MANUAL VALVE LEVER SHAFT OIL SEAL


    1. A01BFQQ

      Using screwdriver, remove the 2 manual valve lever shaft oil seals.

  34. REMOVE OIL PUMP ASSEMBLY


    1. A01BDPD

      Stand up the transmission.

    2. Remove the 7 bolts holding the oil pump to the transmission case.

    3. A01BGFVE01

      Using SST, remove the oil pump.

      SST
      09610-20012

    4. Remove the O-ring from the oil pump.

    5. A01BC3N

      Remove the race from the oil pump.

  35. REMOVE OVERDRIVE PLANETARY GEAR ASSEMBLY


    1. A01BH1R

      Remove the O/D planetary gear, O/D direct clutch and one-way clutch from the transmission case.

    2. A01BBLB

      Remove the bearing and the race.

    3. A01BALK

      Remove the race and bearing.

  36. REMOVE OVERDRIVE PLANETARY RING GEAR


    1. A01BGA8

      Remove the O/D planetary ring gear from the transmission case.

  37. INSPECT OVERDRIVE BRAKE PISTON


    1. A01BDBHE01

      Place SST and a dial indicator onto the O/D brake piston.

      SST
      09350-30020   ( 09350-06120 )
    2. A01BHL5

      Measure the stroke while applying and releasing compressed air (392 to 785 kPa, 4.0 to 8.0 kgf/cm2, 57 to 114 psi).

      Piston stroke
      1.40 to 1.70 mm (0.0551 to 0.0669 in.)

      If the piston stroke is less than the limit, parts may have been assembled incorrectly, so check and reassemble again.

      If the piston stroke is outside the standard, select another flange.

      Tech Tips

      There are 7 different thicknesses for the flange.

      Flange thickness:
      No. Thickness No. Thickness
      77 3.3 mm (0.130 in.) 81 3.8 mm (0.150 in.)
      78 3.5 mm (0.138 in.) 82 3.9 mm (0.154 in.)
      79 3.6 mm (0.142 in.) 83 4.0 mm (0.157 in.)
      80 3.7 mm (0.146 in.) - -

  38. REMOVE OVERDRIVE BRAKE PACK


    1. A01BH49

      Using a screwdriver, remove the snap ring.

    2. A01BEHV

      Remove the overdrive brake pack.

  39. INSPECT PISTON STROKE OF 2ND COAST BRAKE


    1. A01BECFE01

      Place a mark on the 2nd coast brake piston rod as shown in the illustration.

    2. A01BI1GE01

      Using SST, measure the stroke while applying and releasing compressed air (392 to 785 kPa, 4.0 to 8.0 kgf/cm2, 57 to 114 psi).

      SST
      09240-00020
      Piston stroke
      1.5 to 3.0 mm (0.059 to 0.018 in.)

      If the stroke is outside the standard, inspect the brake band.

  40. REMOVE 2ND COAST BRAKE PISTON


    1. A01BCPRE01

      Using SST, remove the snap ring.

      SST
      09350-30020   ( 09350-07060 )
    2. A01BHAG

      Applying compressed air to the oil hole, remove the 2nd coast brake cover, piston and spring.

    3. Remove the 2 O-rings from the cover.

  41. REMOVE OVERDRIVE SUPPORT SUB-ASSEMBLY


    1. A01BF2J

      Remove the bearing.

    2. A01BAK3

      Remove the 2 bolts holding the O/D support sub-assembly to the case.

    3. A01BAGJE01

      Using SST, remove the snap ring.

      SST
      09350-30020   ( 09350-07060 )
    4. A01BAOPE01

      Using SST, remove the O/D support sub-assembly.

      SST
      09350-30020   ( 09350-07020 )
    5. A01BGR9

      Remove the race.

  42. REMOVE DIRECT CLUTCH ASSEMBLY


    1. A01BA95

      Remove the direct clutch with the forward clutch from the case.

    2. A01BECL

      Remove the 2 bearings and the race.

    3. A01BEYDE01

      Remove the direct clutch from the forward clutch.

    4. Remove the bearing and thrust washer from the forward clutch.

  43. REMOVE 2ND COAST BRAKE BAND ASSEMBLY


    1. A01BGNC

      Using a screwdriver, remove the E-ring from the pin.

    2. A01BABM

      Remove the 2nd coast brake band from the case.

    3. Remove the pin from the brake band.

    4. Remove the E-ring from the pin.

  44. REMOVE FRONT PLANETARY RING GEAR SUB-ASSEMBLY


    1. A01BEN1

      Remove the race.

    2. A01BE7W

      Remove the front planetary ring gear from the case,

    3. A01BEAF

      Remove the bearing and race.

    4. A01BEB3

      Remove the race from the front planetary gear.

  45. INSPECT FRONT PLANETARY RING GEAR SUB-ASSEMBLY


    1. A01BDKA

      Using a dial indicator, measure the inside diameter of the planetary ring gear bushing.

      Maximum inside diameter
      24.65 mm (0.9705 in.)

      If the inside diameter is greater than the maximum, replace the planetary ring gear.

  46. REMOVE FRONT PLANETARY GEAR ASSEMBLY


    1. A01BEVNE01

      With wooden blocks or equivalent under the output shaft, stand the transmission on the output shaft.

    2. A01BG5EE01

      Using SST, remove the snap ring.

      SST
      09350-30020   ( 09350-07070 )
    3. A01BB93

      Remove the front planetary gear from the case.

    4. A01BAXU

      Using a screwdriver, remove the bearing and the race from the front planetary gear.

  47. INSPECT PLANETARY PINION GEAR THRUST CLEARANCE


    1. A01BCMH

      Using a feeler gauge, measure the planetary pinion gear thrust clearance.

      Standard clearance
      0.20 to 0.60 mm (0.0079 to 0.0236 in.)
      Maximum clearance
      0.65 mm (0.0256 in.)

      If the clearance is greater than the maximum, replace the planetary gear assembly.

  48. REMOVE PLANETARY SUN GEAR SUB-ASSEMBLY


    1. A01BBOX

      Remove the planetary sun gear sub-assembly.

    2. Remove the thrust washer.

  49. INSPECT PACK CLEARANCE OF SECOND BRAKE


    1. A01BBCB

      Using a feeler gauge, measure the clearance between the snap ring and the flange.

      Clearance
      0.62 to 1.98 mm (0.0244 to 0.0780 in.)

      If the clearance is outside the standard, inspect the discs.

  50. REMOVE 2ND BRAKE PACK


    1. A01BBC5

      Using a screwdriver, remove the snap ring.

    2. A01BF5Y

      Remove the flange, the plates and the discs as a set.

  51. INSPECT PACK CLEARANCE OF FIRST AND REVERSE BRAKE


    1. A01BDE3

      Using a feeler gauge, measure the clearance between the plate and the 2nd brake drum.

      Clearance
      0.70 to 1.22 mm (0.0276 to 0.048 in.)

      If the clearance is outside the standard, inspect the discs.

      Tech Tips

      There are 8 different thicknesses for the flange.

      Flange thickness:
      No. Thickness No. Thickness
      67 5.4 mm (0.213 in.) 52 4.6 mm (0.181 in.)
      66 5.2 mm (0.205 in.) 53 4.4 mm (0.173 in.)
      50 5.0 mm (0.197 in.) 54 4.2 mm (0.165 in.)
      51 4.8 mm (0.189 in.) 55 4.0 mm (0.157 in.)

  52. REMOVE 2ND BRAKE PISTON SLEEVE


    1. A01BEJQ

      Using a screwdriver, remove the 2nd brake piston sleeve.

  53. REMOVE REAR PLANETARY GEAR ASSEMBLY


    1. A01BABCE02

      Using SST and a screwdriver, remove the snap ring.

      SST
      09350-30020   ( 09350-07060 )
    2. A01BGGB

      Remove the rear planetary gear, the 2nd brake drum, the 1st and reverse brake pack and output shaft as an assembly.

    3. A01BE0V

      Remove the bearing from the case.

    4. A01BHGO

      Remove the 2nd brake drum.

    5. A01BF8I

      Remove the cushion plate, the flange, the plates and the discs of the 1st and reverse brake.

    6. A01BEO8

      Remove the leaf spring.

  54. INSPECT 1ST AND REVERSE BRAKE CLUTCH DISC


    1. A01BGSDE01

      Using vernier calipers, measure the return spring free length together with the spring seat.

      Standard free length
      12.9 mm (0.508 in.)

  55. REMOVE BRAKE DRUM GASKET


    1. A01BCPM

      Remove the brake drum gasket.

  56. INSPECT PISTON STROKE OF 1ST AND REVERSE BRAKE


    1. A01BB9J

      Make sure the 1st & reverse brake pistons move smoothly when applying and releasing the compressed air into the transmission case.

  57. REMOVE 1ST AND REVERSE BRAKE RETURN SPRING SUB-ASSEMBLY


    1. A01BGSGE02

      Set SST on the spring retainer, and compress the return spring.

      SST
      09350-30020   ( 09350-07050, 09350-07070 )

    2. Using snap ring pliers, remove the snap ring.

    3. Remove the piston return spring.

    4. Hold the 1st and reverse brake piston by hand, and apply compressed air to the transmission case to remove the 1st and reverse brake piston.

  58. REMOVE 1ST AND REVERSE BRAKE PISTON NO.2


    1. A01BD18

      Remove the 1st and reverse brake piston.

      If the piston does not pop out with compressed air, lift the piston out with the needle-nose pliers.

    2. Remove the O-ring from the 1st and reverse brake piston.

  59. REMOVE BRAKE REACTION SLEEVE


    1. A01BC77E01

      Install SST behind the reaction sleeve and gradually lift it out of the transmission case.

      SST
      09350-30020   ( 09350-07080 )

    2. Remove the O-ring from the reaction sleeve.

  60. REMOVE 1ST AND REVERSE BRAKE PISTON NO.1


    1. A01BCUWE01

      Install SST behind the 1st and reverse brake piston No.1, and gradually lift it out of the transmission case.

      SST
      09350-30020   ( 09350-07090 )

    2. Remove the 2 O-rings from the 1st and reverse brake piston No.1.

  61. INSPECT AUTOMATIC TRANSMISSION CASE SUB-ASSEMBLY


    1. A01BB7Z

      Using a cylinder gauge, measure the inside diameter of the transmission case rear bushing.

      Maximum inside diameter
      38.19 mm(1.5035 in.)

      If the inside diameter is greater than the maximum, replace the transmission case.