Separate Basic Subassembly

1. REMOVE TWO OIL COOLER PIPES

2. REMOVE TRANSMISSION DIPSTICK AND FILLER TUBE

3. REMOVE NEUTRAL START SWITCH

(a) Remove the manual shift lever.

(b) Pry off the lock washer and remove the manual valve shaft nut.

(c) Remove the two bolts and pull out the neutral start switch.

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4. REMOVE UNION

(a) Using the open end wrench, remove the union.

(b) Remove the O-ring from union.

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5. REMOVE THROTTLE CABLE RETAINING BOLT AND PLATE

6. REMOVE SOLENOID WIRE RETAINING BOLT AND PLATE

7. REMOVE SPEED SENSOR AND SENSOR ROTOR

(a) Remove the retaining plate and pull out the speed sensor.

(b) Remove the O-ring from speed sensor.

(c) Remove the two bolts and sensor cover bracket.

(d) Using a screwdriver, remove the sensor cover. HINT: Tape the screwdriver tip before use so as not to damage the cover or transaxle.

(e) Remove the O-ring from the sensor cover.

(f) Remove the sensor rotor.

(g) Remove the three bolts and sensor adaptor.

Sensor Rotor 2001 Rav4

8. REMOVE PAN AND GASKET

(a) Remove the eighteen bolts.

(b) Remove the pan by lifting the transmission case.

NOTICE: Do not turn the transmission over as it will contaminate the valve body with the foreign materials in the bottom of the pan.

(c) Remove the gasket.

(d) Place the transmission on wooden blocks to prevent damage to the pipes.

9. EXAMINE PARTICLES IN PAN

Remove the magnets and use them to collect any steel chips. Lock carefully at the chips and particles in the pan and on the magnet to anticipate what type of wear you will find in the transmission:

Steel (magnetic) .. bearing, gear and plate wear Brass (non-magnetic) .. bushing wear

10. TURN TRANSMISSION OVER

11. REMOVE OIL STRAINER

(a) Remove the three bolts and oil strainer.

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(b) Remove the gasket.

12. REMOVE OIL TUBES

(a) Remove the two bolts and tube bracket.

(b) Remove the tube clamp bolt and clamp.

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(c) Pry up both ends with a large screwdriver and remove the five tubes.

13. REMOVE MANUAL DETENT SPRING

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14. DISCONNECT SOLENOID CONNECTORS

Wire Retainer

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15. REMOVE VALVE BODY

(a) Remove the twelve bolts and wire retainer as shown.

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(b) Disconnect the throttle cable from the cam.

(c) While disconnecting the manual valve connecting rod from the manual valve lever, remove the valve body.

(d) Remove the manual valve from the valve body.

1991 Toyota Mr2 Accelerator Cable

16. REMOVE THROTTLE CABLE FROM CASE

Pull out the throttle cable.

17. REMOVE SOLENOID WIRE

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18. REMOVE SECOND BRAKE APPLY GASKET

19. REMOVE SECOND BRAKE DRUM SEAL

Using a needle nose pliers, pull out the second brake drum seal.

20. REMOVE C3 ACCUMULATOR PISTON AND SPRING

Using low-pressure compressed air (1 kg/cm2,14 psi or 98 kPa) pop out the piston into a rag. Force air into the hole shown and remove the piston and spring.

21. REMOVE ACCUMULATOR PISTONS AND SPRINGS

(a) Loosen the five bolts one turn at a time until the spring tension is released.

(b) Remove the cover and gasket.

(c) Remove the C, piston and two springs.

(d) Using low-pressure compressed air (1 kg/cm2, 14 psi, 98 kPa), pop out the C2 piston into a rag. Force air into the hole shown and remove the piston and spring.

(e) Using low-pressure compressed air (1 kg/cm2, 14 psi, 98 kPa), pop out the B2 piston into a rag. Force air into the hole shown and remove the piston and spring.

22. MEASURE PISTON STROKE OF SECOND COAST BRAKE

(a) Apply a small amount of paint to the piston rod at the point it meets the case as shown in the illustration.

(b) Using SST, measure the piston stroke applying and releasing the compressed air (4-8 kg/cm2, 57 -114 psi, 392 - 785 kPa) as shown.

SST 09240-00020

If the piston stroke exceeds the limit, inspect the brake band.

23. REMOVE SECOND COAST BRAKE PISTON

(a) Using SST, remove the snap ring. SST 09350-32014 (09351 -32050)

(b) Using low-pressure compressed air (1 kg/cm2, 14 psi, 98 kPa), pop out the cover into a rag. Force air into the hole shown.

(c) Remove the cover, piston and spring.

(d) Remove the two O-rings from the cover.

25. REMOVE DIRECT CLUTCH

24. REMOVE OIL PUMP

(a) Remove the six bolts holding the oil pump to the transmission case.

(b) Using SST, pull the oil pump free from the transmission case.

SST 09350-32014 (09351 -32061)

(c) Remove the oil pump with SST.

SST 09350-32014 (09351 -32061)

NOTICE: Be careful not to drop or damage the races and bearing behind oil pump.

(d) Remove SST from the oil pump.

(e) Remove the race from the oil pump.

(f) Remove the O-ring from the oil pump.

25. REMOVE DIRECT CLUTCH

26. REMOVE FORWARD CLUTCH

(a) Remove the forward clutch with bearing and race.

(b) Remove the thrust washer, bearings and races from the forward clutch.

27. REMOVE SECOND COAST BRAKE BAND

(a) Push the pin with a small screwdriver and remove it from the bolt hole of the oil pump mounting.

(b) Remove the brake band.

28. REMOVE FRONT PLANETARY RING GEAR

(a) Remove the front planetary ring gear with race.

(b) Remove the races from the ring gear.

29. REMOVE FRONT PLANETARY GEAR

(a) Remove the front planetary gear with bearing and race.

(b) Remove the races and bearings from the planetary gear.

30. REMOVE SUN GEAR, SUN GEAR INPUT DRUM AND THRUST WASHER

31. REMOVE SECOND BRAKE HUB AND NO. 1 ONE-WAY CLUTCH

32. CONFIRM THAT SECOND BRAKE PISTON MOVES

Using compressed air, confirm that the second brake piston moves smoothly.

33. REMOVE SECOND COAST BRAKE BAND GUIDE

34. REMOVE SNAP RING HOLDING SECOND BRAKE DRUM TO CASE

35. REMOVE SECOND BRAKE DRUM

HINT: If the brake drum is difficult to remove, lightly tap it with a wooden block.

36. REMOVE SECOND BRAKE PISTON RETURN SPRING

(a) Remove the thrust washer.

(b) Remove the return spring.

37. REMOVE PLATES, DISCS AND FLANGE

1991 Mr2 Gear Switches

38. REMOVE SNAP RING HOLDING NO. 2 ONE-WAY CLUTCH OUTER RACE TO CASE

Using a screwdriver, remove the snap ring.

39. REMOVE NO. 2 ONE-WAY CLUTCH AND REAR PLANETARY GEAR

(a) Remove the No. 2 one-way clutch and rear planetary gear with thrust washer.

(b) Remove the thrust washer from the gear.

40. REMOVE REAR PLANETARY RING GEAR

(a) Remove the rear planetary ring gear with bearing and races.

(b) Remove the bearing and races from the ring gear.

41. CONFIRM THAT FIRST AND REVERSE BRAKE PISTON MOVES

Using compressed air, confirm that the first and reverse brake piston moves smoothly.

42. REMOVE SNAP RING HOLDING FLANGE TO CASE

Using a screwdriver, remove the snap ring.

43. REMOVE FLANGES, PLATES AND DISCS

44. REMOVE ENGINE MOUNTING LEFT BRACKET

45. REMOVE TRANSAXLE REAR COVER

(a) Remove the thirteen bolts.

49. REMOVE DIFFERENTIAL

(b) Tap off the circumference of the cover with a plastic hammer to remove the cover from the transmission case, and remove the cover.

46. REMOVE INTERMEDIATE SHAFT

Remove the intermediate shaft from the transmission case.

47. REMOVE SNAP RING

Using snap ring pliers, remove the snap ring.

48. REMOVE TRANSAXLE HOUSING

Remove the nineteen bolts and transaxle housing.

49. REMOVE DIFFERENTIAL

50. REMOVE GOVERNOR DRIVEN GEAR

(a) Remove the governor driven gear.

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51. REMOVE APPLY GASKETS

Remove the two gaskets.

(b) Remove the thrust washer.

51. REMOVE APPLY GASKETS

Remove the two gaskets.

52. REMOVE COUNTER SHAFT LOCK NUTS

(a) Using a chisel and hammer, unstake the counter shaft lock nut on both sides.

(b) Using SST, remove the lock nut of the driven gear side.

SST 09330-00021, 09350-32014 (09351-32032)

(c) Using SST to hold the driven gear, remove the lock nut of the another side.

SST 09330-00021 and

09350-32014 (09351-32032, 09351-32170)

53. REMOVE COUNTER DRIVEN GEAR

Using SST, remove the driven gear. SST 09350-32014 (09351 -32061)

54. REMOVE THRUST NEEDLE BEARING

55. REMOVE COUNTER SHAFT ASSEMBLY

Pull out the counter shaft assembly.

56. REMOVE THRUST BEARING WITH RACE

Remove the thrust bearing with race from the counter shaft assembly.

57. CHECK PISTON STROKE OF UNDERDRIVE CLUTCH

(a) Set a dial indicator (long type pick or SST) as shown.

SST 09350-32014 (09351 -32190)

(b) Applying and releasing the compressed air (4-8 kg/cm2, 57 - 114 psi, 392 - 785 kPa), measure the underdrive clutch piston stroke.

Piston stroke: 1.22 - 1.54 mm (0.0480 - 0.0606 in.)

If the piston stroke is nonstandard, select another flange.

HINT: There are two different flange thickness.

Flange thickness: 2.30 mm (0.0906 in.)

58. REMOVE UNDERDRIVE CLUTCH DRUM AND ANTI-RATTLE CLIP

59. CONFIRM THAT UNDERDRIVE BRAKE PISTON MOVES

Using compressed air, confirm that the underdrive brake piston moves smoothly.

60. REMOVE OIL SEAL RINGS

Remove the two oil seal rings.

61. REMOVE FLANGE, PLATES AND DISCS

(a) Using SST and press, press in the flange until the snap ring is free from the flange.

SST 09350-32014 (09351 -32070)

(b) Using a screwdriver, remove the snap ring.

(c) Remove the flange, three plates and discs.

62. REMOVE RETURN SPRING

63. REMOVE UNDERDRIVE BRAKE PISTON

Using low-pressure compressed air (1 kg/cm2, 14 psi, 98 kPa), pop out the brake piston into a rag. Force air into the hole shown and remove the brake piston.

64. REMOVE O-RINGS FROM PISTON

Remove the two O-rings from the piston.

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65. REMOVE SNAP RING

(a) Set SST, and tighten the bolt gradually to compress the springs until the snap ring is free from the spring seat.

SST 09350-32014 (09351 -32040)

(b) Using snap ring pliers, remove the snap ring.

SST 09350-32014 (09351-32040)

66. REMOVE RETURN SPRING

Remove the return spring and snap ring.

67. REMOVE PISTON FROM TRANSMISSION CASE WITH COMPRESSED AIR

(a) Apply compressed air into the oil passage of the case to remove the piston.

HINT: Hold the piston so it is not slanted and blow with the gun slightly away from the oil hole.

(b) If the piston does not pop out with compressed air, use needle-nose pliers to remove it.

68. REMOVE O-RINGS FROM PISTON

Remove the two O-rings from the piston.

69. REMOVE PARKING LOCK PAWL STOPPER PLATE, TORSION SPRING AND SPRING GUIDE

70. REMOVE PAWL SHAFT CLAMP

Remove the bolt and pawl shaft clamp.

71. REMOVE PARKING LOCK PAWL SHAFT AND LOCK PAWL

72. REMOVE PARKING LOCK SLEEVE

73. REMOVE CAM GUIDE BRACKET

Remove the cam guide bracket as shown.

74. REMOVE MANUAL VALVE SHAFT SPACER

Using a screwdriver and hammer, unstake the spacer and remove it.

75. REMOVEPIN

Using a punch and hammer, drive out the pin.

76. REMOVE MANUAL VALVE SHAFT AND LEVER

(a) Remove the retaining spring.

(b) Slide out the manual valve shaft and remove the manual valve lever and washer.

77. IF NECESSARY, REPLACE OIL SEAL OF MANUAL SHAFT

(a) Using a screwdriver, remove the oil seal.

80. REMOVE BEARING

Using SST, remove the bearing. SST 09308-00010

(b) Using a 14 mm socket wrench and hammer, drive in a new oil seal.

(c) Apply MP grease to the oil seal lip.

78. REMOVE OIL GALLERY COVER AND GASKET

(a) Remove the three bolts.

(b) Using a torx wrench, remove the six screws. Remove the gallery cover and gasket.

79. REMOVE B4 ACCUMULATOR PISTON AND SPRING

80. REMOVE BEARING

Using SST, remove the bearing. SST 09308-00010

81. REMOVE OIL TUBES

(a) Remove the four tube clamps from transaxle housing.

Cartoons Chain Responsibility

(b) Using a screwdriver, remove the three oil tubes.

82. REMOVE OIL TUBE APPLY COVER AND GASKET

Remove the three bolts, and remove the cover and gasket.

83. REMOVE BEARING

(a) Remove the bolt and retainer.

83. REMOVE BEARING

(a) Remove the bolt and retainer.

(b) Using SST, remove the bearing. SST 09308-00010

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    How to change the con rod bearings on a mk2 toyota mr2?
    8 years ago

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