Transmission Disassembly
- Remove torque converter. Remove oil supply tube. Remove speed sensor. Unbolt and remove transfer case adapter case. Remove park/neutral position switch. Remove snap ring from output shaft and remove speed sensor rotor.
- Remove oil pump bolts. Using appropriate 2-jaw puller, remove oil pump from transmission case. Remove bearing and race from rear of oil pump. Remove converter housing bolts. Note length and bolt location. While holding input shaft, remove converter housing. Remove "O" ring from OD case.
- Remove oil pan and gasket. Remove magnets from oil pan. Inspect magnets and pan for metal or brass particles. Remove oil tubes by carefully prying both ends of tube with a screwdriver. See Fig 1. Remove solenoid wiring connectors from transmission case. Remove the oil strainer (filter) and gasket. Remove the valve body assembly. Refer to VALVE BODY ASSEMBLY under ON-VEHICLE SERVICE.
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- Remove throttle cable and "O" ring. Place shop cloth over accumulator pistons. Apply compressed air to oil passages of transmission case to remove accumulator pistons and springs. Air passages are at base of accumulator bores. See Fig 2. Note spring and piston locations.
- Remove parking lock rod bracket and rod. Remove parking lock pawl, pivot pin and spring. If manual valve lever shaft requires removal, use hammer and chisel to cut spacer and slide spacer toward lever to obtain clearance to shaft pin. Drive out roll pin. Remove shaft and spacer. Remove oil seals.
- Position transmission case with front of case facing upward. Push input shaft and drum toward rear of transmission case to ensure OD direct clutch is installed correctly. Using vernier caliper and appropriate thrust plate gauge (straightedge), measure distance between top of case and OD direct clutch drum. See Fig 3.
- Record measurement for reassembly reference. Remove OD planetary gear with OD direct clutch and one-way clutch from OD case. Note location of thrust washer and race on clutch assembly. Hold both sides of OD case and remove from transmission case. Note location of bearing and race. See Fig 4.
- Push input shaft and drum toward rear of transmission case. Ensure forward clutch is installed correctly. Using vernier caliper and thrust plate gauge (staightedge), measure distance between top of case and forward clutch drum. See Fig 5. Record measurement for reassembly reference.
Courtesy of SUZUKI OF AMERICA CORP.
Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
- Remove forward clutch assembly from transmission case. Note location of bearings and race. Remove direct clutch assembly. Remove center support-to-case retaining bolts. Bolts are located at valve body side of case.
- Remove center support and sun gear shaft assembly from transmission case. Note direction of bearing race on end of sun gear. Using 2 screwdrivers, remove front planetary gear snap ring. Remove snap ring. Insert 2 wires into planetary gear and remove gear. Using calipers, measure pack clearance of reverse brake between disc and transmission case. See Fig 6. Pack clearance should be .029-.098" (.72-2.50 mm). If clearance is not as specified, inspect brake discs.
- Remove reverse brake pack and pressure plate. Remove rear planetary gear, output shaft and 2 bearings. Remove brake applying cover. See Fig 7. Remove race from transmission case. Ensure reverse brake pistons move smoothly when applying compressed air into transmission case. See Fig 8.
- Using appropriate spring compressor, compress 1st and reverse brake return spring. Remove snap ring. Remove piston return spring. Hold outer piston with hand, apply compressed air to case and remove outer piston. Gradually lift reaction sleeve out of transmission case. Lift piston out of transmission case. See Fig 4.
Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
Courtesy of SUZUKI OF AMERICA CORP.
Courtesy of SUZUKI OF AMERICA CORP.