AUTOMATIC TRANSMISSION ASSEMBLY (for 1GD-FTV) INSTALLATION


  1. INSTALL TORQUE CONVERTER CLUTCH ASSEMBLY


    1. A003FRCE01
      Text in Illustration
      *1 Flywheel
      *2 Straightedge
      *a Engine Assembly Surface
      *b Drive Plate Surface

      Using a vernier caliper and straightedge, measure the dimension (A) between the automatic transmission assembly contact surface of the engine assembly and torque converter assembly contact surface of the drive plate and ring gear sub-assembly.

      Measurement Method
      a - b = A
    2. A003HBEE01
      Text in Illustration
      *a Matchmark

      Align the matchmark on the automatic transmission case sub-assembly 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.

    3. A003DV2E01
      Text in Illustration
      *1 Front Oil Pump Oil Seal

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

      Note


      • Do not damage the front oil pump oil seal.

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

    4. A003DN2E01
      Text in Illustration
      *1 Front Oil Pump Oil Seal

      Rotate the torque converter assembly approximately 180° again, align the matchmark on the torque converter assembly with the one on the automatic transmission case sub-assembly and insert the key of the torque converter assembly into the groove of the oil pump drive gear.

      Note


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

      • Do not damage the front oil pump oil seal.

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

    5. A003B3CE01

      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
      A + 1 mm (0.0394 in.) or more

      Note


      • Make sure to deduct the thickness of the straightedge.

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

  2. INSTALL WIRING HARNESS CLAMP BRACKET


    1. Install the 2 wire harness clamp brackets to the automatic transmission assembly with the 2 bolts.

      A003ADYE01
      Torque:
      for bolt A
      13 N*m  { 130 kgf*cm, 9 ft.*lbf }
      for bolt B
      8.0 N*m  { 82 kgf*cm, 71 in.*lbf }

  3. INSTALL REAR ENGINE MOUNTING INSULATOR ASSEMBLY

    A003AQ0

    1. Install the rear engine mounting insulator with the 4 bolts.

      Torque:
      29 N*m  { 296 kgf*cm, 21 ft.*lbf }

  4. INSTALL AUTOMATIC TRANSMISSION ASSEMBLY


    1. A003BN2E01
      Text in Illustration
      *1 Crankshaft
      *2 Torque Converter Assembly Centerpiece
      A003DCD Clutch Spline Grease

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

      Clutch spline grease
      Toyota Genuine Clutch Spline Grease or equivalent
      Maximum spread
      About 1 g (0.0353 oz.)
    2. A003CCV

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

    3. While keeping the engine assembly and automatic transmission assembly horizontal, align the 2 knock pins with the holes in the automatic transmission assembly and install the 5 bolts.

      Torque:
      71 N*m  { 724 kgf*cm, 52 ft.*lbf }

      Note


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

      • Check that the torque converter assembly rotates.

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

  5. CONNECT REAR ENGINE MOUNTING INSULATOR ASSEMBLY


    1. A003FKQ

      Connect the rear engine mounting insulator assembly to the body with the bolt, nut and 2 washers.

      Torque:
      98 N*m  { 999 kgf*cm, 72 ft.*lbf }

  6. CONNECT GROUND CABLE


    1. A003AQT

      Connect the ground cable with the bolt.

      Torque:
      13 N*m  { 130 kgf*cm, 9 ft.*lbf }

    2. Connect the ground cable clamp.

  7. CONNECT WIRE HARNESS


    1. Connect the 3 wire harness clamps to the automatic transmission assembly.

      A003FMR

    2. Connect the park/neutral position switch connector, transmission wire connector and 2 transmission revolution sensor connectors.

      Tech Tips

      Push up the lever until the claw of the transmission wire connector makes a connection sound.

  8. CONNECT OIL COOLER TUBE


    1. Connect the ends of the 2 oil cooler tubes to the automatic transmission assembly by hand.

      A003GYKE01

    2. Connect the 3 oil cooler tube clamps with the 4 bolts.

      Torque:
      for bolt A
      8.0 N*m  { 82 kgf*cm, 71 in.*lbf }
      for bolt B
      12 N*m  { 122 kgf*cm, 9 ft.*lbf }
    3. A003H96E01
      Text in Illustration
      *a Torque Wrench Fulcrum Length

      Using a 17 mm union nut wrench, tighten the 2 oil cooler tubes to the automatic transmission assembly

      Torque:
      34 N*m  { 347 kgf*cm, 25 ft.*lbf }

      Tech Tips


      • Calculate the torque wrench reading when changing the fulcrum length of the torque wrench.

        Click here

      • When using a union nut wrench (fulcrum length of 30 mm (1.1811 in.)) + torque wrench (fulcrum length of 180 mm (7.0866 in.)): 29 N*m (297 kgf*cm, 21 ft.*lbf)

    4. A003GCM

      Connect the wire harness clamp to the oil cooler tube clamp.

  9. INSTALL DRIVE PLATE AND TORQUE CONVERTER SETTING BOLT


    1. A003CZO

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

      Torque:
      48 N*m  { 489 kgf*cm, 35 ft.*lbf }

      Note

      Install the black colored bolt first, and then the 5 silver colored bolts.

  10. INSTALL NO. 2 REAR END PLATE


    1. A003CUW

      Install the No. 2 rear end plate with the 3 bolts.

      Torque:
      73 N*m  { 744 kgf*cm, 54 ft.*lbf }

  11. INSTALL NO. 4 CYLINDER BLOCK INSULATOR


    1. A003DJ8

      Install the No. 4 cylinder block insulator.

  12. INSTALL NO. 1 TRANSMISSION CONTROL CABLE BRACKET


    1. A003AKZ

      Install the No. 1 transmission control cable bracket to the automatic transmission assembly with the 2 bolts.

      Torque:
      14 N*m  { 143 kgf*cm, 10 ft.*lbf }

  13. CONNECT TRANSMISSION CONTROL CABLE ASSEMBLY


    1. A003G72E01

      Turn the control shaft lever clockwise until it stops, and then return the control shaft lever counterclockwise 2 notches to N.

    2. A003G90

      Connect the end of the transmission control cable assembly to the transmission control shaft lever LH.

    3. Move the shift lever to N, and with the cable end lightly pushed toward the front of the vehicle, install the transmission control cable assembly to the transmission control shaft lever LH with the nut.

      Torque:
      15 N*m  { 148 kgf*cm, 11 ft.*lbf }

      Tech Tips

      Tighten the nut with no slack in the control cable.

    4. Connect the transmission control cable assembly to the No. 1 transmission control cable bracket with a new clip.

  14. INSTALL FRONT EXHAUST PIPE ASSEMBLY

    Click here

  15. INSTALL STARTER ASSEMBLY

    Click here

  16. INSTALL PROPELLER SHAFT WITH CENTER BEARING ASSEMBLY

    Click here

  17. ADD AUTOMATIC TRANSMISSION FLUID


    1. Fill the transmission with the correct amount of fluid as listed in the table below.

      Standard Capacity
      Performed Repair Engine Type Fill Amount
      Automatic transmission assembly replacement (when reusing the torque converter assembly) 1TR-FE, 2TR-FE 2.5 liters (2.6 US qts, 2.2 Imp. qts)
      1GD-FTV 4.4 liters (4.6 US qts, 3.9 Imp. qts)
      Removal and installation of the automatic transmission oil pan sub-assembly and drain plug 1TR-FE, 2TR-FE 1.0 liters (1.1 US qts, 0.9 Imp. qts)
      1GD-FTV 2.5 liters (2.6 US qts, 2.2 Imp. qts)
      Removal and installation of the transmission valve body assembly 1TR-FE, 2TR-FE 1.7 liters (1.8 US qts, 1.5 Imp. qts)
      1GD-FTV 3.3 liters (3.5 US qts, 2.9 Imp. qts)
      Torque converter assembly replacement 1TR-FE, 2TR-FE 2.5 liters (2.6 US qts, 2.2 Imp. qts)
      1GD-FTV 4.4 liters (4.6 US qts, 3.9 Imp. qts)

      Tech Tips

      If the specified amount of automatic transmission fluid cannot be added, perform the following:


      1. Temporarily install the O-ring and refill plug to the automatic transmission assembly.

        Tech Tips

        Reuse the old O-ring as the refill plug will be removed again to adjust the fluid level.

      2. Lower the vehicle.

      3. Start the engine.

        Note

        To reduce load, make sure that all electrical systems, such as the air conditioning, lighting system, electric fan and audio system, are off.

      4. Slowly move the shift lever from P to S, then move the shift lever to P.

      5. Allow the engine to idle for 30 seconds to warm it up.

      6. Turn the ignition switch off.

      7. Remove the refill plug and O-ring from the automatic transmission assembly.

      8. Fill the automatic transmission assembly with the correct amount of automatic transmission fluid as listed in the table above.

      9. Temporarily install the O-ring and refill plug to the automatic transmission assembly.

        Tech Tips

        Reuse the old O-ring as the refill plug will be removed again to adjust the fluid level.

  18. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

    Note

    When disconnecting the cable, some systems need to be initialized after the cable is reconnected Click here.

  19. INSPECT SHIFT LEVER POSITION


    1. When moving the shift lever from P to R with the ignition switch to ON and the brake pedal depressed, make sure that the shift lever moves smoothly and correctly to P.

    2. Make sure that the shifting lever moves smoothly and can be moderately operated.

    3. When starting the engine, make sure that the vehicle moves forward when shifting from N to D and moves rearward when shifting to R.

  20. ADJUST AUTOMATIC TRANSMISSION FLUID

    Click here

  21. INSPECT FOR EXHAUST GAS LEAK


    • If gas is leaking, tighten the areas necessary to stop the leak. Replace damaged parts as necessary.

  22. INSPECT FOR AUTOMATIC TRANSMISSION FLUID LEAK

  23. INSTALL NO. 2 ENGINE UNDER COVER


    1. Install the No. 2 engine under cover to the body with the 6 bolts.

      Torque:
      13 N*m  { 133 kgf*cm, 10 ft.*lbf }