AUTOMATIC TRANSAXLE ASSEMBLY INSTALLATION

PROCEDURE


  1. INSPECT TORQUE CONVERTER ASSEMBLY

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  2. INSTALL TORQUE CONVERTER ASSEMBLY


    1. A01VZJBE03
      Text in Illustration
      *a Matchmark
      *b Key

      Turn the front oil pump drive gear so that the key is at the top and place a matchmark on the transaxle housing to indicate the position of the key.

      Note

      To prevent damage to the stator shaft assembly when installing the torque converter assembly, make sure to place the matchmark on the correct location shown in the illustration.

    2. A01W0AVE02
      Text in Illustration
      *a Groove
      *b Matchmark

      Place a matchmark on the torque converter assembly so that the position of its groove is clearly indicated.

    3. A01VZHPE02
      Text in Illustration
      *1 Front Oil Pump Oil Seal
      *a Matchmark

      Align the matchmark on the transaxle housing with the one on the torque converter assembly and engage the splines of the input shaft with the turbine runner splines.

      Note


      • Install the torque converter assembly to the input shaft while keeping it horizontal.

      • Do not damage the front oil pump oil seal.

    4. A01VZO4E02
      Text in Illustration
      *1 Front Oil Pump Oil Seal
      *a Matchmark

      Rotate the torque converter assembly approximately 180° and engage the splines of the stator shaft with the stator assembly.

      Note


      • Install the torque converter assembly to the input shaft while keeping it horizontal.

      • Do not push the torque converter assembly excessively when rotating it.

      • Do not damage the front oil pump oil seal.

    5. A01VZCCE02
      Text in Illustration
      *1 Front Oil Pump Oil Seal
      *a Matchmark

      Rotate the torque converter assembly approximately 180° again, align the matchmark on the torque converter assembly with the one on the transaxle housing and insert the groove of the torque converter assembly into the key of the oil pump drive gear.

      Note


      • Install the torque converter assembly to the input shaft while keeping it horizontal.

      • Do not push the torque converter assembly excessively when rotating it.

      • Do not damage the front oil pump oil seal.

    6. Clean the drive plate and torque converter assembly setting bolt holes.

    7. A01W4SHE02
      Text in Illustration
      *a Engine Surface
      *b Drive Plate Surface

      Using a vernier caliper and straightedge, measure the dimension (A) between the automatic transaxle assembly contact surface of the engine*a and the torque converter assembly contact surfaces of the drive plate*b.

      Note

      Make sure to deduct the thickness of the straightedge.

    8. A01W49OE03

      Using a vernier caliper and straightedge, measure the dimension (B) shown in the illustration and check that the dimension (B) is more than the dimension (A), which was measured in the previous step.

      Standard
      B = A + 1 mm (0.0394 in.) or more

      Note


      • Make sure to deduct the thickness of the straightedge.

      • If the automatic transaxle assembly is installed to the engine assembly with the torque converter assembly not sufficiently inserted, the torque converter assembly may be damaged.

      • Do not include the thickness of the set block.

  3. INSTALL TRANSMISSION CASE PLUG ASSEMBLY


    1. Coat a new O-ring with ATF and install it to the transmission case plug assembly.

    2. Install the transmission case plug assembly to the transaxle housing.

  4. INSTALL WIRE HARNESS CLAMP BRACKET


    1. Install the 3 wire harness clamp brackets to the transaxle case sub-assembly with the 3 bolts.

      Torque:
      8.0 N*m  { 82 kgf*cm, 71 in.*lbf }

    2. Install the wire harness clamp bracket to the rear transaxle cover sub-assembly with the bolt.

      Torque:
      8.0 N*m  { 82 kgf*cm, 71 in.*lbf }

  5. INSTALL NO. 1 TRANSMISSION CONTROL CABLE BRACKET


    1. Install the No. 1 transmission control cable bracket to the transaxle case sub-assembly with the 2 bolts.

      Torque:
      12 N*m  { 122 kgf*cm, 9 ft.*lbf }

  6. INSTALL AUTOMATIC TRANSAXLE ASSEMBLY


    1. A01W1MGE03
      Text in Illustration
      *1 Crankshaft
      *2 Torque Converter Assembly Centerpiece

      Apply clutch spline grease to the surface of the crankshaft that contacts the torque converter assembly centerpiece.

      Clutch Spline Grease
      Toyota Genuine Clutch Spline Grease or equivalent
      Maximum Grease Amount
      Approximately 1 g (0.0353 oz)
    2. A01W181E02
      Text in Illustration
      *1 Knock Pin

      Confirm that the 2 knock pins are installed to the engine assembly and are not damaged.

    3. While keeping the engine assembly and automatic transaxle assembly horizontal, align the 2 knock pins with the holes in the automatic transaxle assembly and install the 9 bolts shown in the illustration.

      Bolt Bolt Length Torque
      (A) 55 mm (2.17 in.) 64 N*m (653 kgf*cm, 47 ft.*lbf)
      (B) 50 mm (1.97 in.) 46 N*m (469 kgf*cm, 34 ft.*lbf)
      (C) 32 mm (1.26 in.) 44 N*m (449 kgf*cm, 32 ft.*lbf)
      33 mm (1.30 in.) 43 N*m (438 kgf*cm, 32 ft.*lbf)

      Note


      • When tightening the bolts, make sure that the contact surfaces of the engine assembly and automatic transaxle assembly are in close contact with one another.

      • Do not use excessive force when installing the automatic transaxle assembly.

      • Check that the torque converter assembly rotates.

      • Make sure that the wire harness and other similar items are not pinched between the contact surfaces.

      • In order to protect the automatic transaxle oil pan sub-assembly, place attachments on the transmission jack.

      • Make sure that the attachments and automatic transaxle oil pan sub-assembly are centered on the transmission jack.

      • To prevent the automatic transaxle oil pan sub-assembly from being deformed, do not place any attachments under the automatic transaxle oil pan sub-assembly.

      • Secure the automatic transaxle assembly to the transmission jack using a belt, etc. to prevent it from falling.

  7. INSTALL FRONT ENGINE MOUNTING BRACKET


    1. Install the front engine mounting bracket to the transaxle housing with the 3 bolts.

      Torque:
      64 N*m  { 653 kgf*cm, 47 ft.*lbf }

  8. INSTALL TRANSMISSION OIL COOLER


    1. A01W569E02

      Temporarily install the transmission oil cooler to the front engine mounting bracket with the bolt (A).

    2. Install the bolt (B) to the transmission oil cooler.

      Torque:
      14 N*m  { 138 kgf*cm, 10 ft.*lbf }

    3. Install the bolt (C) to the transmission oil cooler.

      Torque:
      14 N*m  { 138 kgf*cm, 10 ft.*lbf }

    4. Tighten the bolt (A).

      Torque:
      14 N*m  { 138 kgf*cm, 10 ft.*lbf }

    5. Install the outlet oil cooler hose to the oil cooler union sub-assembly and transmission oil cooler, and slide the 2 clips to secure it.

    6. Install the inlet oil cooler hose to the oil cooler inlet elbow and transmission oil cooler, and slide the 2 clips to secure it.

    7. Install the No. 4 water by-pass hose to the No. 1 water by-pass pipe and transmission oil cooler and slide the 2 clips to secure it.

  9. CONNECT ENGINE WIRE


    1. Connect the oil pump with motor assembly connector.

    2. Engage the 4 clamps.

    3. Install the nut.

      Torque:
      8.0 N*m  { 82 kgf*cm, 71 in.*lbf }

    4. Connect the park/neutral position switch assembly connector.

    5. Install the bolt.

      Torque:
      12 N*m  { 122 kgf*cm, 9 ft.*lbf }

  10. INSTALL WIRE HARNESS CLAMP BRACKET


    1. Install the wire harness clamp bracket to the transaxle housing with the bolt.

      Torque:
      20 N*m  { 204 kgf*cm, 15 ft.*lbf }

    2. Engage the 4 clamps to connect the wire harness to the wire harness clamp bracket.

    3. Connect the oxygen sensor connector.

    4. Install the clamp to the wire harness clamp bracket.

    5. Connect the transmission breather hose sub-assembly to the clamp.

  11. INSTALL WIRING HARNESS CONNECTOR


    1. Temporarily install the wiring harness connector to the transaxle case sub-assembly.

    2. A01W3QCE02

      Install the wiring harness connector with the 2 bolts in the order shown in the illustration.

      Torque:
      11 N*m  { 115 kgf*cm, 8 ft.*lbf }
    3. A01W34GE02
      Text in Illustration
      *a Lever

      Connect the connector of the wiring harness connector and push down the lever to engage the claw.

      Tech Tips

      Push down the lever until the claw of the connector of the wiring harness connector makes a click sound.

    4. Engage the wire harness clamp.

  12. INSTALL STARTER ASSEMBLY

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  13. INSTALL FRONT FRAME ASSEMBLY

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  14. INSTALL ENGINE ASSEMBLY WITH TRANSAXLE

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  15. INSTALL DRIVE PLATE AND TORQUE CONVERTER ASSEMBLY SETTING BOLT


    1. A01W139E01
      Text in Illustration
      *a Adhesive

      Apply a few drops of adhesive to 2 or 3 threads at the tip of each of the 6 drive plate and torque converter assembly setting bolts.

      Adhesive
      Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

      Note

      In order to ensure proper installation of the 6 drive plate and torque converter assembly setting bolts, apply adhesive to the 6 drive plate and torque converter assembly setting bolts and install them within 10 minutes of adhesive application.

    2. Turn the crankshaft to gain access to the installation locations of the 6 drive plate and torque converter assembly setting bolts and install each drive plate and torque converter assembly setting bolt while holding the crankshaft pulley bolt with a wrench.

      Torque:
      41 N*m  { 418 kgf*cm, 30 ft.*lbf }

      Note

      First install the black colored bolt, and then the remaining 5 silver colored bolts.

  16. INSTALL FLYWHEEL HOUSING UNDER COVER

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  17. CHECK AUTOMATIC TRANSAXLE SYSTEM

    Note

    If automatic transmission parts have been replaced, refer to the Parts Replacement Compensation Table to determine if any additional operations are necessary Click here.