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.

3. REMOVE OIL COOLER TUBE UNION

Remove the 2 oil cooler tube unions.

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

4. REMOVE SPEED SENSOR

Remove the 2 bolts and 2 speed sensors.

Remove the 2 O-rings from the sensors.

5. REMOVE AUTOMATIC TRANSMISSION BREATHER TUBE

Remove the 2 bolts.

Remove the breather tube.

Remove the O-ring from the tube.

6. REMOVE AUTOMATIC TRANSMISSION HOUSING

Remove the 10 bolts.

Remove the transmission housing.

7. REMOVE REAR ADAPTOR TRANSFER

Remove the 8 bolts.

Remove the transmission case adapter.

HINT:

Use a brass bar and a hammer to remove the transmission case adapter.

8. REMOVE TRANSMISSION CASE ADAPTER REAR OIL SEAL

Using a screwdriver, pry out the oil seal.

NOTICE:

Be careful not to damage the transmission case.

HINT:

Wrap the tip of the screwdriver with tape.

9. REMOVE TRANSFER CASE ADAPTER RADIAL BALL BEARING

Using a screwdriver, remove the snap ring.

Using SST and a press, press out the bearing.

SST
09950-60010(09951-00650)
09950-70010(09951-07150)

10. FIX AUTOMATIC TRANSMISSION CASE SUB-ASSEMBLY

Install the transmission case to an overhaul attachment.

11. REMOVE AUTOMATIC TRANSMISSION OIL PAN SUB-ASSEMBLY

NOTICE:

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

Remove the drain plug and 20 bolts.

12. INSPECT AUTOMATIC TRANSMISSION OIL PAN SUB-ASSEMBLY

Remove the magnets, and use them to collect steel particles.

Carefully look at the foreign matter and particles in the pan and on the magnets to anticipate the type of wear you will find in the transmission.

Steel (magnetic): bearing, gear and clutch plate wear

Brass (non-magnetic): bushing wear

13. REMOVE VALVE BODY OIL STRAINER ASSEMBLY

Turn over the transmission.

Remove the 4 bolts and oil strainer from the valve body.

Remove the O-ring from the oil strainer.

14. REMOVE TRANSMISSION WIRE

Remove the 2 bolts and 2 clamps, and disconnect the 2 ATF temperature sensors.

Disconnect the 7 connectors from the solenoid valves.

Remove the bolt from the case.

Pull the transmission wire out of the transmission case.

Remove the O-ring from the transmission wire.

15. REMOVE TRANSMISSION VALVE BODY ASSEMBLY

Remove the bolt, detent spring cover and detent spring.

Remove the 19 bolts.

Remove the valve body.

16. REMOVE TRANSMISSION CASE GASKET

Remove the 3 gaskets.

17. REMOVE BRAKE DRUM GASKET

Remove the 3 gaskets.

18. REMOVE CHECK BALL BODY

Remove the check ball body and spring.

19. REMOVE C-2 ACCUMULATOR PISTON

Apply compressed air to the oil hole to remove the C-2 accumulator piston and spring.

Remove the 2 O-rings from the piston.

NOTICE:

Be careful as the C-3 and B-3 accumulator pistons may jump out.

20. REMOVE B-3 ACCUMULATOR PISTON

Apply compressed air to the oil hole to remove the B-3 accumulator piston and spring.

Remove the 2 O-rings from the piston.

NOTICE:

Be careful as the C-3 accumulator piston may jump out.

21. REMOVE C-3 ACCUMULATOR PISTON

Apply compressed air to the oil hole to remove the C-3 accumulator piston and 2 springs.

Remove the 2 O-rings from the piston.

22. REMOVE C-1 ACCUMULATOR VALVE

Remove the C-1 accumulator valve and 2 springs.

23. REMOVE PARKING LOCK PAWL BRACKET

Remove the 3 bolts and bracket.

24. REMOVE PARKING LOCK ROD SUB-ASSEMBLY

Disconnect the parking lock rod from the manual valve lever.

25. REMOVE PARKING LOCK PAWL SHAFT

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

Remove the E-ring from the shaft.

26. REMOVE MANUAL VALVE LEVER SUB-ASSEMBLY

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

Using a pin punch and hammer, tap out the spring pin.

HINT:

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

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

27. REMOVE MANUAL VALVE LEVER SHAFT OIL SEAL

Using a screwdriver, pry out the 2 oil seals.

NOTICE:

Be careful not to damage the transmission case.

HINT:

Wrap the tip of the screwdriver with tape.

28. REMOVE OIL PUMP ASSEMBLY

Remove the 10 bolts.

Using SST, remove the oil pump.

SST
09350-30020(09350-07020)

Remove the 2 thrust bearing races from the front oil pump.

29. REMOVE CLUTCH DRUM AND INPUT SHAFT ASSEMBLY

Remove the clutch drum and input shaft assembly from the transmission case.

Remove the clutch drum thrust washer and 2 thrust needle roller bearings.

30. INSPECT NO. 2 1-WAY CLUTCH ASSEMBLY

Hold the reverse clutch hub and turn the 1-way clutch assembly.

Check that the 1-way clutch turns freely clockwise and locks when turned counterclockwise.

31. REMOVE NO. 2 1-WAY CLUTCH ASSEMBLY

Remove the 1-way clutch and No. 2 clutch drum thrust washer from the clutch drum and input shaft assembly.

32. FIX CLUTCH DRUM AND INPUT SHAFT ASSEMBLY

Place the oil pump onto the torque converter, and then place the clutch drum and input shaft assembly onto the oil pump.

33. REMOVE REVERSE CLUTCH HUB SUB-ASSEMBLY

Using a screwdriver, remove the snap ring.

Remove the reverse clutch hub sub-assembly, reverse clutch reaction sleeve, clutch cushion, plate reverse clutch flange, 5 reverse clutch discs and 4 clutch plates from the clutch drum.

34. REMOVE REVERSE CLUTCH REACTION SLEEVE

Remove the reverse clutch reaction sleeve from the reverse clutch hub.

35. REMOVE REAR CLUTCH DISC

Remove the clutch cushion plate, reverse clutch flange, 5 discs and 4 plates from the reverse clutch hub.

36. INSPECT REAR CLUTCH DISC

Replace all discs if one of the following problems is present: 1) a disc, plate or flange is worn or burnt, 2) the lining of a disc is peeled off or discolored, or 3) the grooves or printed numbers have even a little bit of damage.

NOTICE:

Before assembling new discs, soak them in ATF for at least 15 minutes.

37. INSPECT REVERSE CLUTCH HUB SUB-ASSEMBLY

Using a dial indicator, measure the inside diameter of the reverse clutch hub bush.

Standard inside diameter:
35.812 to 35.837 mm (1.410 to 1.411 in.)

Maximum inside diameter:
35.887 mm (1.413 in.)

If the inside diameter is more than the maximum, replace the reverse clutch hub.

38. REMOVE FORWARD CLUTCH HUB SUB-ASSEMBLY

Remove the forward clutch hub from the clutch drum.

Remove the 2 thrust needle roller bearings from the forward clutch hub.

39. INSPECT FORWARD CLUTCH HUB SUB-ASSEMBLY

Using a dial indicator, measure the inside diameter of the forward clutch hub bush.

Standard inside diameter:
26.037 to 26.062 mm (1.025 to 1.026 in.)

Maximum inside diameter:
26.112 mm (1.028 in.)

If the inside diameter is more than the maximum, replace the forward clutch hub.

40. REMOVE MULTIPLE DISC CLUTCH HUB

Remove the multiple disc clutch hub from the clutch drum.

Remove the 2 thrust bearing races from the multiple disc clutch hub.

41. REMOVE INPUT SHAFT ASSEMBLY

Remove the thrust needle roller bearing from the clutch drum.

Remove the input shaft assembly from the clutch drum.

42. REMOVE INPUT SHAFT OIL SEAL RING

Remove the 3 oil seal rings from the input shaft.

43. REMOVE FORWARD MULTIPLE DISC CLUTCH DISC

Using a screwdriver, remove the hole snap ring.

Remove the 2 flanges, 6 discs and 5 plates from the input shaft.

44. INSPECT FORWARD MULTIPLE DISC CLUTCH DISC

NOTICE:

Before assembling new discs, soak them in ATF for at least 15 minutes.

45. REMOVE NO. 1 CLUTCH BALANCER

Place SST on the clutch balancer, and compress the return spring with a press.

SST
09350-30020(09350-07040,09350-07070)

Using a snap ring expander, remove the snap ring.

Remove the clutch balancer and forward clutch return spring from the input shaft assembly.

Remove the O-ring from the No. 1 clutch balancer.

46. INSPECT FORWARD CLUTCH RETURN SPRING SUB-ASSEMBLY

Using a vernier caliper, measure the free length of the spring together with the spring seat.

Standard free length:
26.74 mm (1.05 in.)

47. REMOVE FORWARD CLUTCH PISTON

Hold the input shaft by hand and apply compressed air (392 kPa (4.0 kgf/cm², 57 psi)) to the input shaft to remove the forward clutch piston.

Remove the 2 O-rings from the forward clutch piston.

48. REMOVE REVERSE CLUTCH FLANGE

Remove the reverse clutch flange from the clutch drum.

49. REMOVE DIRECT CLUTCH DISC

Using a screwdriver, remove the 2 hole snap rings from the clutch drum.

Remove the reverse clutch flange, 5 discs and 5 plates from the clutch drum.

50. INSPECT DIRECT CLUTCH DISC

NOTICE:

Before assembling new discs, soak them in ATF for at least 15 minutes.

51. REMOVE NO. 3 CLUTCH BALANCER

Place SST on the clutch balancer, and compress the return spring with a press.

SST
09387-00070

Using SST, remove the snap ring.

SST
09350-30020(09350-07070)

52. REMOVE REVERSE CLUTCH RETURN SPRING SUB-ASSEMBLY

Remove the reverse clutch return spring and O-ring from the reverse clutch piston.

53. INSPECT REVERSE CLUTCH RETURN SPRING SUB-ASSEMBLY

Using a vernier caliper, measure the free length of the spring together with the spring seat.

Standard free length:
21.04 mm (0.828 in.)

54. REMOVE REVERSE CLUTCH PISTON SUB-ASSEMBLY

Remove the reverse clutch piston sub-assembly from the clutch drum.

Remove the O-ring from the reverse clutch piston.

Remove the O-ring from the clutch drum.

55. REMOVE DIRECT CLUTCH PISTON SUB-ASSEMBLY

Place SST on the direct clutch piston, and compress the return spring with a press.

SST
09320-89010

Using SST, remove the snap ring.

SST
09350-30020(09350-07070)

Using 2 screwdrivers, remove the direct clutch piston sub-assembly from the clutch drum.

Remove the O-ring from the clutch drum.

Remove the No. 2 clutch balancer and direct clutch return spring from the direct clutch piston.

Remove the 2 O-rings from the direct clutch piston.

56. INSPECT DIRECT CLUTCH RETURN SPRING SUB-ASSEMBLY

Using a vernier caliper, measure the free length of the spring together with the spring seat.

Standard free length:
19.51 mm (0.768 in.)

57. REMOVE NO. 3 BRAKE SNAP RING

Using a screwdriver, remove the No. 3 brake snap ring from the case.

58. REMOVE NO. 3 BRAKE DISC

Remove the flange, 4 discs, 4 plates and cushion plate from the case.

59. INSPECT NO. 3 BRAKE DISC

NOTICE:

Before assembling new discs, soak them in ATF for at least 15 minutes.

60. REMOVE 2ND BRAKE PISTON HOLE SNAP RING

Using SST, remove the snap ring.

SST
09350-30020(09350-07060)

61. REMOVE 1-WAY CLUTCH ASSEMBLY

Remove the 1-way clutch assembly and No. 1 planetary carrier thrust washer from the case.

62. REMOVE 2ND BRAKE CYLINDER

Remove the 2nd brake cylinder from the case.

63. REMOVE 2ND BRAKE PISTON

Using SST and a press, compress the return spring and remove the snap ring.

SST
09351-40010

Hold the 2nd brake cylinder and apply compressed air (392 kPa (4.0 kgf/cm², 57 psi)) to the 2nd brake cylinder to remove the 2nd brake piston.

Remove the 2 O-rings from the 2nd brake piston.

64. INSPECT NO. 3 BRAKE PISTON RETURN SPRING SUB-ASSEMBLY

Using a vernier caliper, measure the free length of the spring together with the spring seat.

Standard free length:
15.72 mm (0.619 in.)

65. REMOVE FRONT PLANETARY GEAR ASSEMBLY

Remove the front planetary gear assembly and 1-way clutch inner race from the case.

Remove the No. 5 thrust bearing race, thrust needle roller bearing and No. 2 planetary carrier thrust washer from the front planetary gear assembly.

66. INSPECT FRONT PLANETARY GEAR ASSEMBLY

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

Standard clearance:
0.2 to 0.6 mm (0.00787 to 0.0236 in.)

Maximum clearance:
0.65 mm (0.0256 in.)

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

Using a cylinder gauge, measure the inside diameter of the front planetary gear bush.

Maximum inside diameter:
57.48 mm (2.26 in.)

If the inside diameter is more than the maximum, replace the front planetary gear.

67. INSPECT 1-WAY CLUTCH ASSEMBLY

Install the 1-way clutch to the 1-way clutch inner race.

Hold the 1-way clutch inner race and turn the 1-way clutch assembly. Check that the 1-way clutch turns freely counterclockwise and locks when turned clockwise.

Remove the 1-way clutch from the 1-way clutch inner race.

68. REMOVE FRONT PLANETARY RING GEAR

Remove the front planetary ring gear and thrust needle roller bearing from the transmission case.

69. REMOVE CENTER PLANETARY RING GEAR

Using a screwdriver, remove the snap ring.

Remove the center planetary ring gear and front planetary ring gear flange from the front planetary ring gear.

70. REMOVE NO. 1 BRAKE DISC

Remove the flange, 3 discs and 3 plates from the case.

71. INSPECT NO. 1 BRAKE DISC

NOTICE:

Before assembling new discs, soak them in ATF for at least 15 minutes.

72. REMOVE BRAKE PISTON RETURN SPRING SNAP RING

Using a screwdriver, remove the brake piston return spring snap ring from the case.

73. REMOVE BRAKE PISTON RETURN SPRING SUB-ASSEMBLY

Remove the brake piston return spring and No. 1 brake piston with No. 1 brake cylinder from the transmission case.

74. INSPECT BRAKE PISTON RETURN SPRING SUB-ASSEMBLY

Using a vernier caliper, measure the free length of the spring together with the spring seat.

Standard free length:
17.05 mm (0.671 in.)

75. REMOVE NO. 1 BRAKE PISTON

Hold the No. 1 brake cylinder and apply compressed air (392 kPa (4.0 kgf/cm², 57 psi)) to No. 1 brake cylinder to remove the No. 1 brake piston.

HINT:

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

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

76. REMOVE NO. 2 BRAKE DISC

Using a screwdriver, remove the snap ring from the case.

Remove the flange, 3 discs, 3 plates and brake piston return spring from the case.

77. INSPECT NO. 2 BRAKE DISC

NOTICE:

Before assembling new discs, soak them in ATF for at least 15 minutes.

78. INSPECT NO. 2 BRAKE PISTON RETURN SPRING SUB-ASSEMBLY

Using a vernier caliper, measure the free length of the spring together with the spring seat.

Standard free length:
17.05 mm (0.671 in.)

79. REMOVE NO. 2 BRAKE PISTON

Apply compressed air (392 kPa (4.0 kgf/cm², 57 psi)) to the transmission case to remove the No. 2 brake piston.

HINT:

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

Remove the 2 O-rings from the No. 2 brake piston.

80. REMOVE CENTER PLANETARY GEAR ASSEMBLY

Remove the No. 6 thrust bearing race, center planetary gear and planetary sun gear from the case.

81. INSPECT CENTER PLANETARY GEAR ASSEMBLY

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

Standard clearance:
0.12 to 0.68 mm (0.00472 to 0.0268 in.)

Maximum clearance:
0.73 mm (0.0287 in.)

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

82. REMOVE INTERMEDIATE SHAFT

Using a screwdriver, remove the snap ring from the case.

Remove the intermediate shaft with No. 3 1-way clutch assembly from the case.

83. INSPECT NO. 3 1-WAY CLUTCH ASSEMBLY

Hold the rear planetary ring gear flange and turn the 1-way clutch. Check that the 1-way clutch turns freely counterclockwise and locks when turned clockwise.

84. REMOVE NO. 3 1-WAY CLUTCH ASSEMBLY

Remove the No. 3 1-way clutch assembly and 1-way clutch inner race from the intermediate shaft.

85. REMOVE REAR PLANETARY RING GEAR FLANGE SUB-ASSEMBLY

Remove the planetary ring gear flange, No. 7 thrust bearing race, thrust needle roller bearing and No. 8 thrust bearing race from the intermediate shaft.

86. INSPECT REAR PLANETARY RING GEAR FLANGE SUB-ASSEMBLY

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

Standard inside diameter:
32.176 to 32.201 (1.267 to 1.268 in.)

Maximum inside diameter:
32.251 mm (1.270 in.)

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

87. INSPECT INTERMEDIATE SHAFT

Using a dial indicator, measure the intermediate shaft runout.

Standard runout:
0.03 mm (0.00118 in.)

Maximum runout:
0.08 mm (0.00315 in.)

If the runout is more than the maximum, replace the intermediate shaft with a new one.

Using a micrometer, measure the diameter of the intermediate shaft at the positions shown in the diagram.

Standard diameter:
A, B:
25.962 to 25.975 mm (1.022 to 1.023 in.)
C, D:
32.062 to 32.075 mm (1.262 to 1.263 in.)

Minimum diameter:
A, B:
25.912 mm (1.02 in.)
C, D:
32.012 mm (1.26 in.)

If the diameter is less than the minimum, replace the intermediate shaft with a new one.

88. REMOVE BRAKE PLATE STOPPER SPRING

89. REMOVE NO. 4 BRAKE DISC

Remove the 7 plates, 8 discs and 2 flanges from the case.

90. INSPECT NO. 4 BRAKE DISC

NOTICE:

Before assembling new discs, soak them in ATF for at least 15 minutes.

91. REMOVE REAR PLANETARY GEAR ASSEMBLY

Remove the rear planetary gear assembly from the case.

Remove the 2 thrust needle roller bearings from the rear planetary gear.

Remove the No. 9 thrust bearing from the case.

92. INSPECT REAR PLANETARY GEAR ASSEMBLY

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

Standard clearance:
0.2 to 0.6 mm (0.00787 to 0.0236 in.)

Maximum clearance:
0.65 mm (0.0256 in.)

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

Using a dial indicator, measure the inside diameter of the rear planetary gear bush.

Maximum inside diameter:
20.075 mm (0.790 in.)

If the inside diameter is more than the maximum, replace the rear planetary gear assembly.

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

Place SST on the spring retainer and compress the brake return spring.

SST
09350-30020(09350-07050)

Using SST, remove the snap ring and brake return spring.

SST
09350-30020(09350-07070)

94. INSPECT 1ST AND REVERSE BRAKE RETURN SPRING SUB-ASSEMBLY

Using a vernier caliper, measure the free length of the spring together with the spring seat.

Standard free length:
23.74 mm (0.935 in.)

95. REMOVE 1ST AND REVERSE BRAKE PISTON

Apply compressed air (392 kPa (4.0 kgf/cm², 57 psi)) to the transmission case to remove the 1st and reverse brake piston.

HINT:

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

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

96. REMOVE BRAKE REACTION SLEEVE

Using SST, remove the reaction sleeve.

SST
09350-30020(09350-07080)

Remove the O-ring from the reaction sleeve.

97. REMOVE NO. 4 BRAKE PISTON

Using SST, remove the brake piston.

SST
09350-30020(09350-07090)

Remove the 2 O-rings from the brake piston.

A750F AUTOMATIC TRANSMISSION / TRANSAXLE

Land Cruiser URJ200 URJ202 GRJ200 VDJ200

AUTOMATIC TRANSMISSION UNIT