БЛОК АВТОМАТИЧЕСКОЙ ТРАНСМИССИИ РАЗБОРКА


  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. B007SFR

      Remove the bolt and pull out the plug.

    2. Remove the O-ring from the plug.

  5. REMOVE PARK/NEUTRAL POSITION SWITCH ASSEMBLY


    1. B007PQRE01

      Using a screwdriver, pull up the lock washer.

    2. Remove the nut and lock washer.

    3. B007TDG

      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. B007W2W

      Remove the 2 oil cooler tube unions.

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

  7. REMOVE TEMPERATURE SENSOR


    1. B007PQU

      Remove the temperature sensor.

    2. Remove the O-ring from the sensor.

  8. REMOVE SPEED SENSOR


    1. B007VJS

      Remove the bolt and speed sensor.

    2. Remove the O-ring from the sensor.

  9. REMOVE TRANSMISSION REVOLUTION SENSOR


    1. B007VSF

      Remove the bolt and the transmission revolution sensor.

    2. Remove the O-ring from the sensor.

  10. REMOVE EXTENSION HOUSING SUB-ASSEMBLY


    1. B007RU9

      Remove the 6 bolts.

    2. Remove the extension housing and the gasket.

  11. REMOVE EXTENSION HOUSING BUSH APPLY TUBE GASKET


    1. B007W8IE01

      Remove the bush apply tube gasket.

  12. REMOVE EXTENSION HOUSING BUSH APPLY TUBE


    1. B007W8IE03

      Remove the bush apply tube.

  13. REMOVE AUTOMATIC TRANSMISSION EXTENSION HOUSING OIL SEAL


    1. B007VXM

      Using a screwdriver, remove the extension housing oil seal.

  14. REMOVE EXTENSION HOUSING DUST DEFLECTOR


    1. B007U20

      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. B007TAW

      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. B007VPRE01

      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. B007P8S

      Remove the 6 bolts.

    2. Remove the transmission housing.

  18. FIX AUTOMATIC TRANSMISSION CASE SUB-ASSEMBLY


    1. B007UMS

      Install the transmission case on the overhaul attachment.

  19. REMOVE AUTOMATIC TRANSMISSION OIL PAN SUB-ASSEMBLY


    1. B007SGC

      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. B007WA4E04

      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. B007UTVE03

      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. B007T8B

      Remove the 4 bolts and oil strainer case.

  22. REMOVE TRANSMISSION WIRE


    1. B007T4B

      Disconnect the 4 connectors from each shift solenoid valve.

    2. B007PJ1

      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. B007TO0

      Remove the 20 bolts.

  24. REMOVE CHECK BALL BODY


    1. B007Q8Y

      Remove the check ball body and the spring.

  25. REMOVE B-2 ACCUMULATOR PISTON


    1. B007TXF

      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. B007TXF

      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. B007P05

      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. B007VOM

      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. B007Q8S

      Remove the 3 bolts and the parking lock pawl bracket.

  30. REMOVE PARKING LOCK ROD SUB-ASSEMBLY


    1. B007OQD

      Disconnect the parking lock rod from the manual valve lever.

  31. REMOVE PARKING LOCK PAWL SHAFT


    1. B007UWFE01

      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. B007VCJE01

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

    2. B007VT7

      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. B007OPC

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

  34. REMOVE OIL PUMP ASSEMBLY


    1. B007PYE

      Stand up the transmission.

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

    3. B007TFUE01

      Using SST, remove the oil pump.

      SST
      09610-20012

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

    5. B007VDM

      Remove the race from the oil pump.

  35. REMOVE OVERDRIVE PLANETARY GEAR ASSEMBLY


    1. B007P15

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

    2. B007UZZ

      Remove the bearing and the race.

    3. B007TCH

      Remove the race and bearing.

  36. REMOVE OVERDRIVE PLANETARY RING GEAR


    1. B007P92

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

  37. INSPECT OVERDRIVE BRAKE PISTON


    1. B007SQJE01

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

      SST
      09350-30020   ( 09350-06120 )
    2. B007QHU

      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. B007TOR

      Using a screwdriver, remove the snap ring.

    2. B007RZ6

      Remove the overdrive brake pack.

  39. INSPECT PISTON STROKE OF 2ND COAST BRAKE


    1. B007W6QE01

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

    2. B007VQME01

      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. B007RORE01

      Using SST, remove the snap ring.

      SST
      09350-30020   ( 09350-07060 )
    2. B007RQ3

      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. B007R5M

      Remove the bearing.

    2. B007U78

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

    3. B007VZ2E01

      Using SST, remove the snap ring.

      SST
      09350-30020   ( 09350-07060 )
    4. B007RX8E01

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

      SST
      09350-30020   ( 09350-07020 )
    5. B007PAY

      Remove the race.

  42. REMOVE DIRECT CLUTCH ASSEMBLY


    1. B007SG7

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

    2. B007UYV

      Remove the 2 bearings and the race.

    3. B007R8VE01

      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. B007V9Y

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

    2. B007PDF

      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. B007Q4P

      Remove the race.

    2. B007W6K

      Remove the front planetary ring gear from the case,

    3. B007P0Q

      Remove the bearing and race.

    4. B007P2T

      Remove the race from the front planetary gear.

  45. INSPECT FRONT PLANETARY RING GEAR SUB-ASSEMBLY


    1. B007V0M

      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. B007SLXE01

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

    2. B007P0HE01

      Using SST, remove the snap ring.

      SST
      09350-30020   ( 09350-07070 )
    3. B007Q0I

      Remove the front planetary gear from the case.

    4. B007VFK

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

  47. INSPECT PLANETARY PINION GEAR THRUST CLEARANCE


    1. B007SF4

      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. B007PC2

      Remove the planetary sun gear sub-assembly.

    2. Remove the thrust washer.

  49. INSPECT PACK CLEARANCE OF SECOND BRAKE


    1. B007URI

      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. B007ODW

      Using a screwdriver, remove the snap ring.

    2. B007Q3V

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

  51. INSPECT PACK CLEARANCE OF FIRST AND REVERSE BRAKE


    1. B007U0M

      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. B007S88

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

  53. REMOVE REAR PLANETARY GEAR ASSEMBLY


    1. B007SDKE02

      Using SST and a screwdriver, remove the snap ring.

      SST
      09350-30020   ( 09350-07060 )
    2. B007S61

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

    3. B007WFM

      Remove the bearing from the case.

    4. B007VTS

      Remove the 2nd brake drum.

    5. B007OUD

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

    6. B007R1V

      Remove the leaf spring.

  54. INSPECT 1ST AND REVERSE BRAKE CLUTCH DISC


    1. B007R2FE01

      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. B007UXK

      Remove the brake drum gasket.

  56. INSPECT PISTON STROKE OF 1ST AND REVERSE BRAKE


    1. B007UST

      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. B007Q8RE02

      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. B007PFD

      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. B007SZQE01

      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. B007PJHE01

      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. B007S1C

      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.