AUTOMATIC TRANSMISSION ASSEMBLY INSTALLATION

CAUTION / NOTICE / HINT

CAUTION:

The automatic transmission assembly is very heavy. Be sure to follow the procedure described in the repair manual, or the transmission jack may suddenly drop.

PROCEDURE


  1. INSTALL TORQUE CONVERTER ASSEMBLY


    1. B001A7CE01
      Text in Illustration
      *a Drive Plate Surface
      *b Engine Assembly Surface

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

    2. B0019UDE02
      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. B001AYBE03
      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. B0018XYE03
      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. B001AJ9E03

      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 + 1.00 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 TRANSFER ASSEMBLY

    Click here

  3. INSTALL LOWER TRANSFER CASE PROTECTOR


    1. Install the lower transfer case protector with the 7 bolts and attach the clamp.

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

  4. INSTALL AUTOMATIC TRANSMISSION ASSEMBLY


    1. B001ADYE05
      Text in Illustration
      *1 Crankshaft
      *2 Torque Converter Assembly Centerpiece
      B0018FC 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. Confirm that the 2 knock pins are installed on the engine assembly and are not damaged.

    3. B001AWBE02

      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 10 bolts.

      Torque:
      for bolt A and bolt C
      71 N*m  { 724 kgf*cm, 52 ft.*lbf }
      for bolt B
      37 N*m  { 377 kgf*cm, 27 ft.*lbf }
      Bolt Length
      Item Length Thread Diameter
      Bolt A 45 mm (1.77 in.) 17 mm (0.669 in.)
      Bolt B 45 mm (1.77 in.) 14 mm (0.551 in.)
      Bolt C 50 mm (1.97 in.) 17 mm (0.669 in.)

      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.

  5. INSTALL OIL PAN COVER


    1. B0019EP

      Install the oil pan cover with the 2 bolts.

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

  6. INSTALL TRANSMISSION HOUSING COVER


    1. B0018XT

      Install the transmission housing cover with the 3 bolts.

      Torque:
      12 N*m  { 117 kgf*cm, 8 ft.*lbf }

  7. CONNECT BREATHER PLUG HOSE

    B001A2B

    1. Connect the 3 breather plug hoses to the wire harness.

  8. CONNECT WIRE HARNESS AND CONNECTOR


    1. Tilt down the automatic transmission assembly.

      Note

      Make sure that the engine assembly does not contact the vehicle body when tilting the automatic transmission assembly.

    2. Connect the park/neutral position switch connector, No. 2 transmission wire connector, 2 speed sensor connectors and 3 transfer control side connectors.

      B0018O3

    3. Connect the No. 1 transmission wire connector.

      Tech Tips

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

    4. Connect the 9 harness clamps.

    5. Connect the wire harness with the 2 bolts.

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

  9. INSTALL REAR NO. 1 ENGINE MOUNTING INSULATOR

    B0019LP

    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 }

  10. INSTALL NO. 2 FRAME CROSSMEMBER SUB-ASSEMBLY

    B001AUK

    1. Install the No. 2 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. B001ATN

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

      Torque:
      110 N*m  { 1122 kgf*cm, 81 ft.*lbf }
    3. B001A95

      w/ Cover:

      Install the engine mounting hole cover.

  11. CONNECT GROUND WIRE


    1. Tilt up the automatic transmission assembly.

    2. B0019GA

      Connect the clamp and ground wire with the bolt.

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

  12. CONNECT OIL COOLER TUBE


    1. B00195ME03
      Text in Illustration
      *a Paint Mark
      *b RH Side

      Connect the 2 transmission oil cooler hoses and slide the 2 clips to secure the hoses as shown in the illustration.

      Note


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

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

    2. Temporarily install the oil cooler tube to the engine with the bolts A and B. Install the bolt C and tighten it to the specified torque. Then tighten the bolts A and B to the specified torque.

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

  13. INSTALL DRIVE PLATE AND TORQUE CONVERTER SETTING BOLT


    1. B0018AN

      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 with a wrench.

      Torque:
      53 N*m  { 540 kgf*cm, 39 ft.*lbf }

      Note

      First install the black colored bolt, and then the remaining 5 silver colored bolts.

    2. B0019N7

      Install the oil pan insulator with the 2 bolts.

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

  14. INSTALL NO. 3 FRONT FLOOR HEAT INSULATOR

    Click here

  15. INSTALL EXHAUST PIPE (w/ DPF)

    Click here

  16. INSTALL EXHAUST PIPE (w/o DPF)

    Click here

  17. INSTALL PROPELLER SHAFT ASSEMBLY

    Click here

  18. INSTALL FRONT PROPELLER SHAFT ASSEMBLY

    Click here

  19. CONNECT FLOOR SHIFT GEAR SHIFTING ROD SUB-ASSEMBLY

    Click here

  20. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

    Note

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

  21. ADD AUTOMATIC TRANSMISSION FLUID

    Click here

  22. 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. B001AP8E01
        Text in Illustration
        *a Lever
        B0018FC Nut
        B00199O Push

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

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

  23. INSPECT FOR EXHAUST GAS LEAK

  24. INSTALL OIL PAN PROTECTOR ASSEMBLY RH (w/ DPF)


    1. B00194Y

      Install the oil pan protector assembly RH with the 4 bolts.

      Torque:
      50 N*m  { 510 kgf*cm, 37 ft.*lbf }

  25. INSTALL OIL PAN PROTECTOR ASSEMBLY LH (w/ DPF)


    1. B001896

      Install the oil pan protector assembly LH with the 6 bolts.

      Torque:
      50 N*m  { 510 kgf*cm, 37 ft.*lbf }

  26. INSTALL OIL PAN PROTECTOR ASSEMBLY (w/o DPF)

    B00193S

    1. Install the oil pan protector assembly with the 4 bolts.

      Torque:
      50 N*m  { 510 kgf*cm, 37 ft.*lbf }

  27. INSTALL FRONT FENDER APRON SEAL REAR RH

    Click here

  28. INSTALL FRONT FENDER APRON SEAL FRONT RH

    Click here

  29. INSTALL NO. 2 ENGINE UNDER COVER

    Click here

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

    Click here

  31. INSTALL FRONT FENDER SPLASH SHIELD SUB-ASSEMBLY LH

    Click here

  32. INSTALL FRONT FENDER SPLASH SHIELD SUB-ASSEMBLY RH

    Click here

  33. RESET MEMORY

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