AUTOMATIC TRANSMISSION ASSEMBLY(for 1GD-FTV) 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 install the 4 wire harness clamp brackets to the wire harness.

  2. INSTALL TORQUE CONVERTER ASSEMBLY


    1. B001DGYN01
      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 (*a) and the torque converter assembly contact surface of the drive plate (*b).

      Measurement Method
      (a)-(b)=(A)
    2. B001CD4E02
      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. B001FCUE02
      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. B001E2TE02
      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. B001HN1E01

      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.

  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 BREATHER BRACKET

    Tech Tips

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


    1. Install the 2 clamps to the transmission breather bracket.

    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 3 breather hoses to the transmission breather bracket.

  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. B001H2IE02

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

      Tech Tips

      Bolt length:


      • Bolt A: 45 mm (1.77 in.)

      • Bolt B: 50 mm (1.97 in.)

  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. 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.

    5. Connect the breather hose to the wire harness.

  9. INSTALL REAR NO. 1 ENGINE MOUNTING INSULATOR

    Tech Tips

    It is not necessary to remove the rear No. 1 engine mounting insulator unless it is being replaced.


    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 front insulator RH 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 }

  10. INSTALL NO. 3 FRAME CROSSMEMBER SUB-ASSEMBLY


    1. B001F5U

      w/ Urea SCR System:

      Remove the bolt as shown in the illustration, raise the urea tank sub-assembly and hold it in position.

      Tech Tips

      Only raise the urea tank enough to install the fixing bolt to the No. 3 frame crossmember sub-assembly. Do not raise it any higher.

    2. B001HIV

      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.

    3. B001F4A

      w/ Urea SCR System:

      Connect the urea tank sub-assembly to the No. 3 frame crossmember sub-assembly with the 2 bolts.

      Torque:
      14 N*m  { 146 kgf*cm, 11 ft.*lbf }
    4. B001FHY

      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 }

  11. INSTALL FRONT SUSPENSION MEMBER BRACKET LH AND RH


    1. B001G5WE02
      Text in Illustration
      *A w/ Urea SCR System
      *A w/o Urea SCR System

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

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

  12. CONNECT OIL COOLER TUBE


    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 engine assembly with the 2 bolt.

      Torque:
      5.5 N*m  { 56 kgf*cm, 49 in.*lbf }

    3. Install the flexible hose clamp with the bolt.

      Torque:
      14 N*m  { 143 kgf*cm, 10 ft.*lbf }
    4. 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)

  13. INSTALL TRANSMISSION INSULATOR RH

    Click here

  14. 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.

  15. INSTALL DRIVE PLATE AND TORQUE CONVERTER ASSEMBLY SETTING BOLT


    1. B001FTJC01
      *a Fulcrum Length
      *b

      Socket Adaptor (Square drive 12.7 mm to 9.5 mm)

      (Tool No. 09022-3C110)
      *c

      Socket Adaptor (Square drive 9.5 mm to 12.7 mm)

      (Tool No. 09022-3C100)
      *d

      17 mm Socket Wrench

      (Tool No. 09011-2C500)
      B001DLW Turn

      Using SST, adapter, 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.

      SST
      09961-01270
      09970-10010   ( 09970-00010 )
      Torque:
      Torque Wrench Fulcrum Length
      48 N*m  { 489 kgf*cm, 35 ft.*lbf }

      Note

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

      Tech Tips


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

        Click here

      • When using SST (fulcrum length of 40 mm (1.57 in.)) + torque wrench (fulcrum length of 255 mm (10.0 in.)): 41.3 N*m (421 kgf*cm, 30 ft.*lbf)

  16. INSTALL OIL PAN INSULATOR


    1. Install the oil pan insulator with the 2 bolts.

      Torque:
      18 N*m  { 184 kgf*cm, 13 ft.*lbf }

    2. Attach the 2 wire harness clamps.

  17. CONNECT STARTER ASSEMBLY


    1. for 2.0 kW Type:


      1. Install the starter assembly with the 2 bolts and nut.

        Torque:
        68 N*m  { 693 kgf*cm, 50 ft.*lbf }

    2. for 2.7 kW Type:


      1. Install the starter assembly with the bolt and 2 nut.

        Torque:
        68 N*m  { 693 kgf*cm, 50 ft.*lbf }

  18. INSTALL FRONT EXHAUST PIPE ASSEMBLY

    Click here

  19. INSTALL FRONT PROPELLER SHAFT ASSEMBLY

    Click here

  20. INSTALL PROPELLER SHAFT ASSEMBLY

    Click here

  21. ADD AUTOMATIC TRANSMISSION FLUID

    Click here

  22. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

    Note

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

    Click here

  23. INSPECT SHIFT LEVER POSITION

    Click here

  24. ADJUST AUTOMATIC TRANSMISSION FLUID

    Click here

  25. INSPECT FOR EXHAUST GAS LEAK

    Click here

  26. INSPECT FOR OIL LEAK


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

  27. INSTALL REAR ENGINE UNDER COVER ASSEMBLY

    Click here

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

    Click here

  29. 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