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AUTOMATIC TRANSAXLE ASSEMBLY INSTALLATION

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CAUTION / NOTICE / HINT

CAUTION:

The engine assembly with transaxle is very heavy. Be sure to follow the procedure described in the repair manual, or the engine lifter may suddenly drop or the engine assembly with transaxle may fall off the engine lifter.

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PROCEDURE


  1. Click here

    INSTALL TORQUE CONVERTER ASSEMBLY


    1. B006YJIC01
      *a Matchmark
      *b Key

      Set the key at the top of the front oil pump drive gear and put a matchmark on the transaxle housing.

    2. B006WS5C02
      *a Groove
      *b Matchmark
      B006Z38 MP Grease

      Apply MP grease to place a matchmark on the torque converter assembly so that the position of its groove is clearly indicated.

    3. B006YR7C01
      *1 Front Oil Pump Oil Seal
      *a Matchmark

      Align the matchmark on the 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. B006ZLNC01
      *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:

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

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

      • Do not damage the front oil pump oil seal.

    5. B007093C01
      *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 housing and insert the groove of the torque converter assembly into the key of the oil pump drive gear.

      Note:

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

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

      • Do not damage the front oil pump oil seal.

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

    7. B0070MZN02

      Using a vernier caliper and straightedge, measure the dimension (A) shown in the illustration and check the dimension (A).

      Standard
      14 mm (0.5512 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.

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    INSTALL WIRE HARNESS CLAMP BRACKET


    1. Install the 4 wire harness clamp brackets to the automatic transaxle case sub-assembly and transmission case side cover with the 4 bolts.

      10 N*m 102 kgf*cm 7 ft.*lbf

    2. Install the wire harness clamp bracket to the automatic transaxle case sub-assembly with the bolt.

      19 N*m 194 kgf*cm 14 ft.*lbf

    3. Install the wire harness clamp bracket to the automatic transaxle case sub-assembly with the bolt.

      20 N*m 204 kgf*cm 15 ft.*lbf
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    INSTALL TRANSMISSION CASE PLUG ASSEMBLY


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

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

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    INSTALL NO. 1 TRANSMISSION CONTROL CABLE BRACKET


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

      12 N*m 122 kgf*cm 9 ft.*lbf
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    INSTALL TRANSMISSION OIL COOLER

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    INSTALL NO. 1 OIL COOLER TUBE SUB-ASSEMBLY WITHOUT HOSE


    1. B006XOXC01
      *a 0 to 3 mm (0 to 0.118 in.)
      *b 2 to 7 mm (0.0787 to 0.276 in.)
      *c Paint Mark
      *d 45° (Claw of Clip Location)

      Connect the outlet No. 2 oil cooler hose to the transmission oil cooler and slide the clip to secure it.

      Note:

      • Make sure to slide the outlet No. 2 oil cooler hose until it contacts the hose stopper of the transmission oil cooler.

      • Make sure to align the paint mark of the outlet No. 2 oil cooler hose with the paint mark of the transmission oil cooler.

      • Make sure that the claws of the clip are within the location shown in the illustration.

    2. B006XCBC01
      *a 0 to 3 mm (0 to 0.118 in.)
      *b 2 to 7 mm (0.0787 to 0.276 in.)
      *c Paint Mark
      *d 45° (Claw of Clip Location)

      Connect the inlet No. 2 oil cooler hose to the transmission oil cooler and slide the clip to secure it.

      Note:

      • Make sure to slide the inlet No. 2 oil cooler hose until it contacts the hose stopper of the transmission oil cooler.

      • Make sure to align the paint mark of the inlet No. 2 oil cooler hose with the paint mark of the transmission oil cooler.

      • Make sure that the claws of the clip are within the location shown in the illustration.

    3. B0070SON01

      Temporarily install the No. 1 oil cooler tube sub-assembly without hose to the automatic transaxle case sub-assembly with the 2 bolts.

    4. Tighten the 2 bolts in the order shown in the illustration.

      13.5 N*m 138 kgf*cm 10 ft.*lbf
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    CONNECT INLET NO. 1 OIL COOLER HOSE

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    CONNECT OUTLET NO. 1 OIL COOLER HOSE

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    INSTALL REAR ENGINE MOUNTING BRACKET SUB-ASSEMBLY


    1. B00704KN01

      Install the rear engine mounting bracket sub-assembly to the transaxle housing with the 4 bolts.

      42 N*m 428 kgf*cm 31 ft.*lbf
      Tip:

      Tightening order: Temporarily tighten bolt (A) → Fully tighten bolt (B) → Fully tighten bolt (A) → Fully tighten bolt (C)

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    INSTALL REAR ENGINE MOUNTING INSULATOR

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    INSTALL ENGINE MOUNTING INSULATOR LH


    1. B006XWDN01

      Install the engine mounting insulator LH to the automatic transaxle case sub-assembly with the 5 bolts.

      42 N*m 428 kgf*cm 31 ft.*lbf
      Tip:

      Tightening order: Temporarily tighten bolt (A) → Fully tighten bolt (B) → Fully tighten bolt (C) → Fully tighten bolt (A) → Fully tighten bolt (D)

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    INSTALL AUTOMATIC TRANSAXLE ASSEMBLY


    1. B00700OC01
      *1 Crankshaft
      *2 Torque Converter Assembly Centerpiece
      B006Z38 Clutch Spline Grease

      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. B0070OKC01
      *1 Knock Pin

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

    3. B006YMWN01

      While keeping the engine assembly and automatic transaxle assembly horizontal, align the knock pins with the holes in the automatic transaxle assembly and install the automatic transaxle assembly with the 8 bolts shown in the illustration.

      Bolt (A)
      64 N*m 653 kgf*cm 47 ft.*lbf
      Bolt (B)
      46 N*m 469 kgf*cm 34 ft.*lbf
      Bolt (C)
      25 N*m 255 kgf*cm 18 ft.*lbf
      Bolt (D)
      46 N*m 469 kgf*cm 34 ft.*lbf
      Bolt Length
      Bolt Length
      (A) 50 mm (1.97 in.)
      (B) 45 mm (1.77 in.)
      (C) 35 mm (1.38 in.)
      (D) 45 mm (1.77 in.)
      Note:

      • Confirm that the knock pins are installed to the automatic transaxle assembly contact surface of the cylinder block sub-assembly before installing the automatic transaxle assembly.

      • Do not forcibly pry on the automatic transaxle assembly.

      • Check that the torque converter assembly rotates.

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    INSTALL FRONT ENGINE MOUNTING BRACKET


    1. B006YJVN01

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

      42 N*m 428 kgf*cm 31 ft.*lbf
      Tip:

      Tightening order: Temporarily tighten bolt (A) → Fully tighten bolt (B) → Fully tighten bolt (C) → Fully tighten bolt (A)

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    INSTALL FRONT FRAME ASSEMBLY

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    INSTALL STARTER ASSEMBLY


    1. Install the starter assembly to the cylinder block sub-assembly with the 2 bolts.

      46 N*m 469 kgf*cm 34 ft.*lbf

    2. Connect the No. 2 engine wire to the terminal 30 with the nut.

      9.8 N*m 100 kgf*cm 87 in.*lbf

    3. Close the terminal cap.

    4. Connect the starter assembly connector.

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    INSTALL FLYWHEEL HOUSING SIDE COVER

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    CONNECT WIRE HARNESS


    1. Engage the wire harness clamp to connect the wire harness to the automatic transaxle assembly.

    2. Install the 2 bolts.

      10 N*m 102 kgf*cm 7 ft.*lbf

    3. Engage the 9 wire harness clamps to connect the wire harness.

    4. Install the bolt.

      10 N*m 102 kgf*cm 7 ft.*lbf
    5. B006ZJH

      Connect the wire harness to the rack and pinion power steering gear assembly with the 2 bolts.

      10 N*m 102 kgf*cm 7 ft.*lbf

    6. Connect the rack and pinion power steering gear assembly connector.

      Note:

      Make sure that the connector is fully inserted before rotating the lock lever to engage the lock.

    7. Engage the wire harness clamp and connect the vacuum switching valve (for active control engine mount system) connector.

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

    9. B006X70

      Connect the connector of the transmission wire connector and rotate the lever and engage the claw.

      Tip:

      Rotate the lever until the claw of the transmission wire connector makes a click sound.

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    INSTALL STEERING GEAR HEAT INSULATOR

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    INSTALL BREATHER PLUG HOSE


    1. Install the breather plug sub-assembly to the breather plug hose.

    2. Install the breather plug hose to the No. 1 breather plug (ATM).

    3. Engage the 2 hose clamps to connect the breather plug hose.

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    CONNECT WATER BY-PASS HOSE ASSEMBLY


    1. B006X9DC01
      *a 2 to 7 mm (0.0787 to 0.276 in.) *b Paint Mark
      *c 45° (Claw of Clip Location) - -

      Connect the water by-pass hose assembly to the transmission oil cooler and slide the clip to secure it.

      Note:

      • Make sure to slide the water by-pass hose assembly until it contacts the hose stopper of the transmission oil cooler.

      • Make sure to align the paint mark of the water by-pass hose assembly with the paint mark of the transmission oil cooler.

      • Make sure that the claws of the clip are within the location shown in the illustration.

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    INSTALL FLOW SHUTTING VALVE (NO. 1 WATER BY-PASS HOSE)

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    CONNECT VACUUM HOSE


    1. Engage the 9 clamps to connect the vacuum hose to the automatic transaxle assembly.

    2. Connect the vacuum hose to the vacuum hose connector.

    3. Connect the vacuum hose to the rear engine mounting insulator.

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    INSTALL DRIVE PLATE AND TORQUE CONVERTER ASSEMBLY SETTING BOLT


    1. Remove any remaining adhesive from the 6 drive plate and torque converter assembly setting bolts.

    2. B006ZVIC22
      *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:

      Make sure to install the 6 drive plate and torque converter assembly setting bolts immediately after applying adhesive to prevent foreign matter from attaching to them.

    3. 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.

      41 N*m 418 kgf*cm 30 ft.*lbf
      Note:

      First install the black colored drive plate and torque converter assembly setting bolt, and then the remaining 5 silver colored drive plate and torque converter assembly setting bolts.

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    INSTALL FLYWHEEL HOUSING UNDER COVER

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    INSTALL ENGINE ASSEMBLY WITH TRANSAXLE

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    CHECK AUTOMATIC TRANSAXLE SYSTEM

    Note:

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

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