Automatic Transmission/Transaxle: Service Precautions

PRECAUTION

NOTICE:
^ The automatic transmission is composed of precision-made parts. Before reassembling, be sure to inspect thoroughly. Even a small nick could cause fluid leakage or affect the transmission performance.
^ The instructions here are organized so that you work on only one component group at a time.
This will help avoid confusion between similar parts on your workbench.
^ The component groups are inspected and repaired from the converter housing side.
^ Whenever possible, complete the inspection, repair and reassembly before proceeding to the next component group. If a defect is found in a certain component group during reassembly, inspect and repair this group immediately. If a component group cannot be assembled because parts are being ordered, be sure to keep all parts of the group in a separate container while proceeding with disassembly, inspection, repair and reassembly of other component groups.
^ Recommended TOYOTA ATF: T-IV
^ All disassembled parts should be washed clean, and compressed air should be blown through any fluid passages and holes.
^ Dry all parts with compressed air. Never use cloth.
^ The recommended automatic transmission fluid or kerosene should be used for cleaning.
^ After cleaning, the parts should be arranged in the order they were removed for efficient inspection, repairs, and reassembly.
^ When disassembling a valve body, be sure to match each valve with its corresponding spring.
^ New discs for the brakes and clutches that will be used for replacement must be soaked in ATF for at least 15 minutes before reassembly.
^ All oil seal rings, clutch discs, clutch plates, rotating parts, and sliding surfaces should be coated with ATF before reassembly.
^ All old gaskets and rubber O-rings must be replaced.
^ Do not apply adhesive cement to gaskets or similar parts.
^ Make sure that the ends of the snap rings are not aligned with one of the cutouts and are installed in the groove correctly.
^ If a worn bushing is to be replaced, the sub-assembly containing the bushing must also be replaced.
^ Check thrust bearings and races for wear or damage. Replace if necessary.
^ Use petroleum jelly to keep parts in place.
^ When working with FIPG material, perform the following:
Using a razor blade and gasket scraper, remove all old FIPG material from the gasket surface. Clean all components thoroughly to remove all foreign matter.
Clean both sealing surfaces with a non-residue solvent.
Apply FIPG material in a bead of approximately 1 mm (0.04 inch) on the sealing surface.
Reassemble parts within 10 minutes of applying FIPG material. Failing to do so will require the FIPG material to be removed and reapplied.

CAUTION: When using compressed air, always aim away from yourself to prevent ATF or kerosene from spraying on your face.