Page 1619 of 4770

INTRODUCTIONGENERAL REPAIR INSTRUCTIONS ±
IN±4
GENERAL REPAIR INSTRUCTIONS
1. Use fender, seat and floor covers to keep the vehicle
clean and prevent damage.
2. During disassembly, keep parts in the appropriate order
to facilitate reassembly.
3. Observe the following:
(a) Before performing electrical work, disconnect the
negative (±) terminal cable from the battery.
(b) If it is necessary to disconnect the battery for inspec-
tion or repair, always disconnect the cable from the
negative (±) terminal which is grounded to the ve-
hicle body.
(c) To prevent damage to the battery terminal post, loos-
en the terminal nut and raise the cable straight up
without twisting or prying it.
(d) Clean the battery terminal posts and cable terminals
with a clean shop rag. Do not scrape them with a file
or other abrasive objects.
(e) Install the cable terminal to the battery post with the
nut loose, and tighten the nut after installation. Do
not use a hammer to tap the terminal onto the post.
(f) Be sure the cover for the positive (+) terminal is prop-
erly in place.
4. Check hose and wiring connectors to make sure that they
are secure and correct.
5. Non±reusable parts
(a) Always replace cotter pins, gaskets, O±rings and oil
seals etc. with new ones.
(b) Non±reusable parts are indicated in the component
illustrations by the ºº symbol.
6. Precoated parts
Precoated parts are bolts and nuts, etc. that are coated
with a seal lock adhesive at the factory.
(a) If a precoated part is retightened, loosened or
caused to move in any way, it must be recoated with
the specified adhesive.
(b) When reusing precoated parts, clean off the old
adhesive and dry with compressed air. Then applyIN022±07
Page 1627 of 4770
AUTOMATIC TRANSAXLESERVICE SPECIFICATIONS ±
AX±12
SERVICE SPECIFICATIONS
SERVICE DATE
Oil Pump
Body clearance STD0.07 ± 0.15 mm
0.0028 ± 0.0059 in.
Maximum0.3 mm
0.012 in.
Tip clearance STD0.11 ± 0.14 mm
0.0043 ± 0.0055 in.
Maximum0.3 mm
0.012 in.
Side clearance STD0.02 ± 0.05 mm
0.0008 ± 0.0020 in.
Maximum0.1 mm
0.004 in.
Pump body bushing inside diameterMaximum38.18 mm
1.5031 in.
Stator shaft bushing inside diameter
Front side
Maximum21.57 mm
0.8492 in.
Rear side
Maximum27.07 mm
1.0657 in.
Direct Clutch
Clutch drum bushing inside diameterMaximum47.07 mm
1.8531 in.
Direct clutch piston stroke1.11 ± 1.44 mm
0.0437 ± 0.0567 in.
Flange thickness
2.60 mm
0.1024 in.
3.00 mm
0.1181 in.
Forward Clutch
Piston stroke1.41 ± 1.82 mm
0.0555 ± 0.0717 in.
Flange thickness
2.8 mm
0.110 in.
3.0 mm
0.118 in.
3.2 mm
0.126 in.
3.4 mm
0.134 in.
3.6 mm
0.142 in.
Front Planetary Gear
AT06P±0C
Page 1629 of 4770

AUTOMATIC TRANSAXLESERVICE SPECIFICATIONS ±
AX±14
Valve Body Spring
SpringFree length and Coil outer
diameter mm (in.)Total No. of coils and Color
Upper valve body
Throttle modulator valve21.7 (0.854)
9.5 (0.374)9.5
None
Accumulator control valve28.1 (0.105)
10.6 (0.417)13.0
Yellow
Low coast modulator valve21.6 (0.850)
7.9 (0.311)11.5
None
Down shift plug29.8 (1.172)
8.7 (0.344)13.5
Yellow
Throttle valve30.7 (1.209)
9.2 (0.362)9.5
None
Second coast modulator valve20.9 (0.824)
8.5 (0.336)10.0
Light Green
Cut±back valve21.8 (0.858)
6.0 (0.236)13.5
None
Lock±up relay valve26.6 (1.046)
10.2 (0.402)11.5
Green
Lower valve body
Pressure relief valve11.2 (0.441)
6.4 (0.252)7.5
None
1 ± 2 shift valve29.3 (1.152)
9.7 (0.382)10.5
None
2 ± 3 shift valve29.3 (1.152)
9.7 (0.382)10.5
None
3 ± 4 shift valve29.3 (1.152)
9.7 (0.382)10.5
None
Primary regulator valve66.7 (2.453)
18.6 (0.732)12.5
None
Secondary regulator valve43.6 (1.717)
10.9 (0.429)11.5
None
Lock±up signal valve30.0 (1.181)
8.2 (0.323)11.5
None
Cooler By±pass valve19.9 (0.784)
11.0 (0.433)8.5
None
Valve Body Retainer
ReteinerHeight
mm (in.)Width
mm (in.)Thickness
mm (in.)
Upper valve body
Throttle Modulator valve9.2 (0.362)5.0 (0.197)3.2 (0.126)
Accumulator control valve11.5 (0.453)5.0 (0.197)3.2 (0.126)
Cut±back valve9.2 (0.591)5.0 (0.197)3.2 (0.126)
Lock±up relay valve15.0 (0.591)5.0 (0.197)3.2 (0.126)
Second coast modulator valve15.0 (0.591)5.0 (0.197)3.2 (0.126)
Lower valve body
Primary regulator valve9.2 (0.362)5.0 (0.197)3.2 (0.126)
Page 1633 of 4770
AUTOMATIC TRANSAXLESERVICE SPECIFICATIONS ±
AX±18
TORQUE SPECIFICATION
Part tightenedN´mkgf´cmft´lbf
Stator shaft x Oil pump body101007
Upper valve body x Lower valve body5.45548
Ring gear x Differential case9798571
Side bearing cap x Transaxle case7273053
Bearing retainer x Transaxle case1919514
Counter drive gear x Drive pinion1721,750127
Carrier cover x Transaxle case2525018
Parking lock pawl bracket7.47565 in.´lbf
Overdrive case x Transaxle case2526019
Oil pump x Transaxle case2222016
Valve body x Transaxle case101007
Manual valve body x Transaxle case101007
Detent spring x Valve body101007
Oil tube bracket x Transaxle case101007
Oil strainer x Valve body101007
Oil pan x Transaxle case4.95043 in.´lbf
Park/Neutral position switch6.97061 in.´lbf
Park/Neutral position switch adjusting bolt5.45548 in.´lbf
Union2727520
AT06Q±0C
Page 1639 of 4770
AUTOMATIC TRANSAXLEOPERATION ±
AX±6
2. HYDRAULIC CONTROL SYSTEM
The hydraulic control system is composed of the oil pump, the valve body, the solenoid valves, the accu-
mulators, the clutches and brakes, and the governor valve as well as the fluid passages which connect
all of these components.
Based on the hydraulic pressure created by the oil pump, the hydraulic control system governs the hy-
draulic pressure acting on the torque converter clutch, clutches and brakes in accordance with the ve-
hicle driving conditions.
There are three solenoid valves on the valve body.
The No.1 and No.2 solenoid valves are turned on and off by signals from the ECM to operate the shift
valves and change the gear shift position.
The No.3 solenoid valve is operated by signals from the ECM to engage or disengage the lock±up
clutch of the torque converter.
Page 1641 of 4770
AUTOMATIC TRANSAXLEPREPARATION ±
AX±8
PREPARATION
SST (SPECIAL SERVICE TOOLS)
09240±00020Wire Gauge Set
09330±00021Companion Flange Holding Tool
09350±32014TOYOTA Automatic Transmission
Tool Set
09308±10010Oil Seal Puller
(09351±32020)Stator Stopper
(09351±32032)Counter Driven Gear Holding Tool
(09351±32040)No.1 Piston Spring Compressor
(09351±32050)Snap Ring Expander
(09351±32061)Oil Pump Puller
(09351±32070)No.2 Piston Spring Compressor
(09351±32080)Lock Nut Wrench
(09351±32090)Oil Seal Remover & Replacer
(09351±32100)Drive Pinion Bearing Replacer
AX0EQ±02
Page 1642 of 4770
AUTOMATIC TRANSAXLEPREPARATION ±
AX±9
(09351±32111)Side Bearing Race Replacer
(09351±32120)Overdrive Bearing Replacer
(09351±32130)Handle
(09351±32140)Oil Seal Replacer
(09351±32150)Oil Seal Replacer
(09351±32190)Measure Terminal
(09351±32200)No.3 Piston Spring Compressor
09502±10012Differential Side Bearing Puller
09564±32011Differential Preload Adaptor
09710±28020Front Suspension Bushing Tool
Set
(09710±08040)Bushing Replacer
09950±00020Bearing Remover
RECOMMENDED TOOL
09031±00030Pin Punch .
AX0ER±02
Page 1649 of 4770
AUTOMATIC TRANSAXLECOMPONENT PARTS REMOVAL ±
AX±16
(b) Remove the cover.
7. REMOVE OIL PAN AND GASKET
(a) Remove the 15 bolts.
(b) Remove the oil pan by lifting transaxle case.
NOTICE: Do not turn the transaxle over as this will contami-
nate the valve body with the foreign materials in the bottom
of the oil pan.
(c) Place the transaxle on wooden blocks to prevent damage
to the tube bracket.
8. EXAMINE PARTICLES IN PAN
Remove the magnets and use them to collect any steel
chips. Look carefully at the chips and particles in the oil
pan and on the magnets to anticipate what type of wear
you will find in the transmission:
Steel (magnetic): bearing, gear and plate wear
Brass (non±magnetic): bushing wear
9. DISCONNECT NO.1 AND NO.2 SOLENOID CONNEC-
TORS
10. REMOVE TUBE BRACKET AND OIL STRAINER