AUTOMATIC TRANSMISSION ASSEMBLY(for 1GR-FE) INSTALLATION

PROCEDURE


  1. INSTALL WIRE HARNESS CLAMP BRACKET

    Tech Tips

    It is not necessary to remove the wire harness clamp brackets unless they are being replaced.


    1. Attach the 8 wire harness clamps and claw and install the 4 wire harness clamp brackets to the wire harness.

    2. w/o ATF Warmer:

      Install the wire harness clamp bracket to the automatic transmission assembly with the bolt.

      Torque:
      13 N*m  { 127 kgf*cm, 9 ft.*lbf }

  2. INSTALL TORQUE CONVERTER ASSEMBLY


    1. B001H1BE02
      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. B001FGAE02
      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. B001DS3E02
      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. B001E1VE02
      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. B001ETCE01

      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.

  3. INSTALL TRANSMISSION OIL PAN HEAT INSULATOR

    Tech Tips

    It is not necessary to remove the transmission oil pan heat insulator unless it is being replaced.


    1. Install the transmission oil pan heat insulator to the automatic transmission assembly with the 3 bolts.

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

  4. INSTALL TRANSMISSION CONTROL CABLE BRACKET

    Tech Tips

    It is not necessary to remove the transmission control cable bracket unless it is being replaced.


    1. Install the transmission control cable bracket to the automatic transmission assembly with the 2 bolts.

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

  5. INSTALL TRANSFER ASSEMBLY

    Click here

  6. INSTALL TRANSMISSION OIL COOLER ASSEMBLY (w/ ATF Warmer)

    Note

    Make sure to install the clips so that the spool fitting is not overlapped.

    Tech Tips

    It is not necessary to remove the transmission oil cooler assembly unless it is being replaced.


    1. B001HZLE03
      Text in Illustration
      *a 2 to 7 mm (0.0788 to 0.2755 in.)

      Temporarily install the transmission oil cooler assembly to the automatic transmission assembly with the bolt labeled A. Install the bolt labeled B and bolt labeled C tighten it to the specified torque. Then tighten the bolt labeled A to the specified torque.

      Torque:
      21 N*m  { 214 kgf*cm, 15 ft.*lbf }

    2. Connect the 2 oil cooler hoses to the automatic transmission assembly, and slide the 2 clips to secure them.

      Note

      Make sure to install any hose clips without a specific installation direction in a direction that does not interfere with other parts.

  7. INSTALL AUTOMATIC TRANSMISSION ASSEMBLY


    1. B001CXFE03
      Text in Illustration
      *1 Crankshaft
      *2 Torque Converter Assembly Centerpiece
      B001CHY 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. B001GHEE03

      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 9 bolts.

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

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

    4. Connect the breather hose to the engine assembly.

  8. CONNECT WIRE HARNESS


    1. Tilt down the automatic transmission assembly.

      Note

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

    2. Connect the wire harness to the automatic transmission assembly with the 4 bolts.

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

    3. Attach the 2 wire harness clamps.

    4. Attach the heated oxygen sensor connector to the wire harness clamp bracket.

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

      Tech Tips

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

    6. Connect the breather hose to the wire harness.

  9. INSTALL TRANSMISSION BREATHER BRACKET


    1. Install the clamp to the transmission breather bracket.

      Tech Tips

      It is not necessary to remove the transmission breather clamp unless it is being replaced.

    2. Install the transmission breather bracket to the automatic transmission assembly with the bolt.

      Torque:
      6.5 N*m  { 66 kgf*cm, 58 in.*lbf }

    3. Connect the 2 breather hoses and attach the wire harness clamp to the transmission breather bracket.

  10. 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:
      73 N*m  { 739 kgf*cm, 53 ft.*lbf }

      Note

      Make sure to install the engine mounting heat insulator so that its installation surface faces the right side of the vehicle.

    2. Install the engine mounting heat insulator to the rear No. 1 engine mounting insulator with the bolt.

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

  11. INSTALL NO. 3 FRAME CROSSMEMBER SUB-ASSEMBLY


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

      Torque:
      72 N*m  { 734 kgf*cm, 53 ft.*lbf }

      Note

      Install the nuts so that they face the rear of the vehicle.

      Tech Tips

      Hold the bolts while tightening the nuts.

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

      Torque:
      30 N*m  { 306 kgf*cm, 22 ft.*lbf }

  12. INSTALL FRONT SUSPENSION MEMBER BRACKET LH AND RH


    1. Install the front suspension member bracket LH and RH with the 8 bolts.

      Torque:
      33 N*m  { 337 kgf*cm, 24 ft.*lbf }

  13. CONNECT WATER BY-PASS PIPE (w/ ATF Warmer)

    Note

    Make sure to install the clips so that the spool fitting is not overlapped.


    1. B001IL0E05
      Text in Illustration
      *a RH Side
      *b 2 to 7 mm (0.0788 to 0.2755 in.)

      Connect the water by-pass pipe to the automatic transmission assembly with the 2 bolts.

      Torque:
      21 N*m  { 214 kgf*cm, 15 ft.*lbf }

    2. Connect the 2 water by-pass hoses to the transmission oil cooler assembly, and slide the 2 clips to secure them.

  14. CONNECT OIL COOLER TUBE (w/ ATF Warmer)


    1. Connect the 2 oil cooler tubes to the automatic transmission assembly and engine assembly with the 2 bolts.

      Torque:
      14 N*m  { 143 kgf*cm, 10 ft.*lbf }
    2. B001FIRE03
      Text in Illustration
      *a Front Side
      *b Lower Side
      *c 2 to 7 mm (0.0788 to 0.2755 in.)

      Connect the 2 oil cooler hoses to the transmission oil cooler assembly, and slide the 2 clips to secure them.

  15. CONNECT OIL COOLER TUBE (w/o ATF Warmer)


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

    2. Connect the 2 oil cooler tubes to the automatic transmission assembly and engine assembly with the 2 bolt.

      Torque:
      14 N*m  { 143 kgf*cm, 10 ft.*lbf }
    3. B001CVIE05
      Text in Illustration
      *a Torque Wrench Fulcrum Length

      Using a 17 mm union nut wrench, tighten the 2 oil cooler tubes.

      Torque:
      Specified tightening torque
      34 N*m  { 350 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 (1.181 in.)) + torque wrench (fulcrum length of 180 mm (7.087 in.)): 29 N*m (300 kgf*cm, 22 ft.*lbf)

  16. INSTALL TRANSMISSION INSULATOR RH

    Click here

  17. CONNECT TRANSMISSION CONTROL CABLE ASSEMBLY


    1. B001FLWE02

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

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

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

      Tech Tips

      Tighten the nut with no slack in the transmission control cable assembly.

    3. Connect the transmission control shift cable assembly to the transmission control cable bracket with a new clip.

  18. INSTALL DRIVE PLATE AND TORQUE CONVERTER ASSEMBLY SETTING BOLT


    1. Turn the crankshaft to gain access to the installation locations of the 6 drive plate and torque converter assembly 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 remaining 5 silver colored bolts.

  19. INSTALL FLYWHEEL HOUSING SIDE COVER


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

  20. INSTALL STARTER ASSEMBLY

    Click here

  21. INSTALL EXHAUST MANIFOLD SUB-ASSEMBLY LH

    Click here

  22. INSTALL EXHAUST MANIFOLD SUB-ASSEMBLY RH

    Click here

  23. INSTALL PROPELLER SHAFT ASSEMBLY

    Click here

  24. INSTALL FRONT PROPELLER SHAFT ASSEMBLY

    Click here

  25. INSTALL INTAKE AIR SURGE TANK

    Click here

  26. ADD AUTOMATIC TRANSMISSION FLUID

    Click here

  27. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

    Note

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

  28. ADD ENGINE COOLANT (w/ ATF Warmer)

    Click here

  29. INSPECT SHIFT LEVER POSITION

    Click here

  30. ADJUST AUTOMATIC TRANSMISSION FLUID

    Click here

  31. INSPECT FOR COOLANT LEAK

    Click here

  32. INSPECT FOR EXHAUST GAS LEAK

    Click here

  33. INSPECT FOR OIL LEAK


    1. Start the engine. Make sure that there are no oil leaks from the areas that were worked on.

  34. INSTALL REAR ENGINE UNDER COVER ASSEMBLY

    Click here

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

    Click here

  36. RESET MEMORY


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

      Click here