AUTOMATIC TRANSMISSION ASSEMBLY INSTALLATION

PROCEDURE


  1. INSPECT TORQUE CONVERTER ASSEMBLY

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  2. INSPECT DRIVE PLATE

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  3. INSTALL TORQUE CONVERTER ASSEMBLY


    1. B001ZI1E02
      Text in Illustration
      *a Engine 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 (*a) and the torque converter assembly contact surface of the drive plate (*b).

    2. B001XIAE02
      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. B001X7TE02
      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. B001ZH1E02
      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. B001Y9YE01

      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 distance
      B = 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.

  4. INSTALL WIRE HARNESS CLAMP BRACKET


    1. Install the 6 harness clamp brackets with the 6 bolts.

      B001Z24C01
      B001XPG Bolt A B001WGT Bolt B (Type A, Type B or Type C)
      *a Bolt Head Length - -
      Torque:
      for bolt A
      8.0 N*m  { 82 kgf*cm, 71 in.*lbf }
      for bolt B (Type A)
      7.5 N*m  { 76 kgf*cm, 66 in.*lbf }
      for bolt B (Type B)
      8.0 N*m  { 82 kgf*cm, 71 in.*lbf }
      for bolt B (Type C)
      13 N*m  { 133 kgf*cm, 10 ft.*lbf }
      Bolt Head Length (Bolt B)
      Item Bolt Head Length
      Type A 4.0 mm (0.157 in.)
      Type B 5.6 mm (0.220 in.)
      Type C 6.0 mm (0.236 in.)

  5. INSTALL TRANSFER ASSEMBLY

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  6. INSTALL LOWER TRANSFER CASE PROTECTOR


    1. Install the lower transfer case protector with the 7 bolts.

      Torque:
      13.6 N*m  { 139 kgf*cm, 10 ft.*lbf }

    2. Attach the clamp of the ground cable to the lower transfer case protector.

  7. INSTALL TRANSFER BREATHER HOSE SUB-ASSEMBLY


    1. B001WTTC01
      *1 Breather Hose

      Connect the 3 breather hoses and install the transfer breather hose sub-assembly to the automatic transmission assembly.

    2. B001WI0

      Connect the 2 breather plug hoses to the harness clamp bracket.

  8. INSTALL AUTOMATIC TRANSMISSION ASSEMBLY

    B001YRJE02

    1. 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. Confirm that the 2 knock pins are on the surface of the engine block that contacts the automatic transmission assembly.

      Text in Illustration
      *1 Torque Converter Assembly Centerpiece
      *2 Knock Pin
      *3 Crankshaft
    3. B001Y5YC01
      B001XPG Bolt A
      B001WGT Bolt B

      Keeping the engine and automatic transmission assembly horizontal, align the knock pins with the holes on the automatic transmission assembly and install the 9 bolts shown in the illustration.

      Torque:
      for 17 mm head bolt A
      71 N*m  { 724 kgf*cm, 52 ft.*lbf }
      for 14 mm head bolt B
      37 N*m  { 377 kgf*cm, 27 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.

      • Make sure that the cooling fan and fan shroud do not contact the engine assembly when tilting the automatic transmission assembly.

  9. CONNECT TRANSMISSION OIL COOLER HOSE


    1. B001ZGNC01
      *a Paint Mark
      *b 0 to 6.0 mm (0 to 0.236 in.)
      *c 2.0 to 7.0 mm (0.0788 to 0.275 in.)

      Connect the 2 transmission oil cooler hoses to the 2 oil cooler tube unions, and slide the 2 hose clips to secure the hose.

      Note


      • Make sure the pinching portion of each hose clip is facing the direction shown in the illustration.

      • Make sure the paint mark of each hose is facing outward.

  10. CONNECT OIL COOLER TUBE SUB-ASSEMBLY


    1. B001VNZN01

      Temporarily install the oil cooler tube sub-assembly to the automatic transmission assembly and engine assembly with bolt A.

    2. Tighten bolt A, and then tighten bolt B.

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

  11. CONNECT WIRE HARNESS AND CONNECTOR


    1. Connect the 13 wire harness clamps and wire harness.

      B001VNA

    2. Connect the park/neutral position switch assembly connector, transmission wire connector, 2 transmission revolutions sensor connectors and 2 transfer control connectors.

      Tech Tips

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

    3. B001Y6K

      Install the 5 wire harness clamps.

    4. Tilt up the automatic transmission assembly.

    5. B001W96

      Connect the ground cable with the bolt.

      Torque:
      8.4 N*m  { 86 kgf*cm, 74 in.*lbf }

  12. INSTALL REAR NO. 1 ENGINE MOUNTING INSULATOR


    1. Install the rear No. 1 engine mounting insulator to the automatic transmission assembly with the 4 bolts.

      Torque:
      59 N*m  { 602 kgf*cm, 44 ft.*lbf }

  13. INSTALL NO. 3 FRAME CROSSMEMBER SUB-ASSEMBLY


    1. Connect the No. 3 frame crossmember sub-assembly to the rear No. 1 engine mounting insulator with the 4 bolts.

      Torque:
      37 N*m  { 377 kgf*cm, 27 ft.*lbf }

    2. Install the No. 3 frame crossmember sub-assembly to the frame with the 4 bolts and 4 nuts.

      Torque:
      110 N*m  { 1122 kgf*cm, 81 ft.*lbf }

  14. INSTALL DRIVE PLATE AND TORQUE CONVERTER SETTING BOLT


    1. Turn the crankshaft to gain access to the installation locations of the 6 bolts and install the bolts while holding the crankshaft pulley set bolt with a wrench.

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

      Note

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

  15. INSTALL FLYWHEEL HOUSING SIDE COVER


    1. Install the flywheel housing side cover to the engine assembly.

  16. INSTALL STARTER ASSEMBLY

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  17. CONNECT FLOOR SHIFT GEAR SHIFTING ROD SUB-ASSEMBLY


    1. B00204XC01
      *1 Transmission Control Shaft Lever RH

      Turn the transmission control shaft lever RH counterclockwise until it stops, and then turn it clockwise 2 notches to set it to the N position.

    2. B001XHB

      Connect the floor shift gear shifting rod sub-assembly to the transmission control shaft lever RH with the pin and a new clip.

  18. INSTALL EXHAUST MANIFOLD SUB-ASSEMBLY RH

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  19. INSTALL EXHAUST MANIFOLD SUB-ASSEMBLY LH

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  20. INSTALL PROPELLER SHAFT ASSEMBLY

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  21. INSTALL FRONT PROPELLER SHAFT ASSEMBLY

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  22. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

    Note

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

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  23. ADD AUTOMATIC TRANSMISSION FLUID

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  24. INSPECT SHIFT LEVER POSITION


    1. When moving the shift lever from P to R with the engine switch on (IG) and the brake pedal depressed, make sure that it moves smoothly and correctly into position.

    2. Check that the shift lever does not stop when moving the shift lever from R to P, and check that the shift lever does not stick when moving the shift lever from D to S.

    3. Start the engine and make sure that the vehicle moves forward after moving the shift lever from N to D, and moves rearward after moving the shift lever to R.

      If there are problems during the above inspections, perform the adjustment using the following procedures.


      1. Move the shift lever to N

      2. B001XSQE02
        Text in Illustration
        *1 Shift Lever

        Loosen the nut of the floor shift gear shifting rod sub-assembly. Then, with the lever of the transmission floor shift assembly lightly pushed towards the rear of the vehicle, tighten the nut.

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

  25. INSPECT FOR EXHAUST GAS LEAK

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  26. INSTALL FRONT FENDER APRON TRIM PACKING C

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  27. INSTALL FRONT FENDER APRON TRIM PACKING A

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  28. INSTALL NO. 2 ENGINE UNDER COVER

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  29. INSTALL NO. 1 ENGINE UNDER COVER SUB-ASSEMBLY

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  30. INSTALL FRONT FENDER SPLASH SHIELD SUB-ASSEMBLY LH

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  31. INSTALL FRONT FENDER SPLASH SHIELD SUB-ASSEMBLY RH

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  32. RESET MEMORY

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