AUTOMATIC TRANSAXLE ASSEMBLY INSTALLATION


  1. INSPECT TORQUE CONVERTER ASSEMBLY


    1. Inspect the one-way clutch.


      1. B000L56

        Press on the splines of the stator with a finger and rotate the stator. Check that the stator rotates smoothly when turned clockwise and rotates with difficulty when turned counterclockwise.

        If necessary, clean the torque converter and recheck the one-way clutch.

        Replace the torque converter if the one-way clutch still fails the inspection.

        Text in Illustration
        B000K70 Difficult
        B000IB9 Smooth
    2. B000ICOE37
      Text in Illustration
      *a Sample showing maximum allowable amount of powder in ATF

      Inspect the torque converter assembly.

      If any of the following problems are present, replace the torque converter assembly.


      • A metallic sound is emitted from the torque converter assembly during the stall test or when the shift lever is moved to N.

      • The one-way clutch turns smoothly or locks in both directions.

      • The amount of powder in the ATF is more than the sample shown in the illustration (refer to the sample).

      Tech Tips

      The sample shows approximately 0.025 liters (0.026 US qts, 0.022 Imp. qts) of ATF that was removed from a torque converter.

    3. Replace the ATF in the torque converter.

      Tech Tips

      If the ATF is discolored or has a foul odor, stir the ATF in the torque converter before replacing the ATF.

    4. B000K80

      Clean and check the oil cooler and oil pipe line.

      Tech Tips


      • If the torque converter is inspected or the ATF is replaced, it is necessary to clean the oil cooler and oil pipe line.

      • Apply compressed air of 196 kPa (2.0 kgf/ cm2, 28 psi) into the inlet hose.

      • If a large amount of powder is found in the ATF, add new ATF using a bucket pump and clean the oil cooler and oil pipe line again.

      • If the ATF is cloudy, inspect the oil cooler.

    5. B000JOBE39
      Text in Illustration
      *a Correct
      *b Incorrect
      *c Bottom is damaged

      Prevent deformation of the torque converter and damage to the oil pump gear.

      Note

      Make sure that all of the bolts are the same length and that the specified bolts are used.

      Tech Tips

      If there is any damage to the tip of a bolt for the torque converter or to the bottom of a bolt hole, replace the bolt and torque converter.

  2. INSTALL TORQUE CONVERTER ASSEMBLY


    1. B000NNF

      Engage the splines of the input shaft and turbine runner.

    2. B000HPY

      Engage the splines of the stator shaft and the stator while turning the torque converter assembly.

      Tech Tips

      If the stator shaft splines are difficult to engage with the stator splines, move the torque converter back approximately 10 mm and engage the splines while rotating the torque converter.

    3. B000KE0

      Turn the torque converter assembly to insert the key of the oil pump drive gear into the groove of the torque converter assembly.

    4. Clean the torque converter set bolt holes.

    5. B000N5LE02
      Text in Illustration
      *a Engine Surface
      *b Drive Plate Surface

      Using a vernier caliper and straightedge, measure dimension A between the transaxle contact surface of the engine and the torque converter contact surface of the drive plate.

      Note

      Make sure to deduct the thickness of the straightedge.

    6. B000LMCE01

      Using a vernier caliper and straightedge, measure dimension B shown in the illustration and check that dimension B is more than 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 transaxle assembly is installed to the engine with the torque converter not sufficiently inserted, the torque converter may be damaged.

  3. INSTALL TRANSMISSION CASE PLUG ASSEMBLY


    1. Apply ATF to a new O-ring and install it to the transmission case plug assembly.

    2. Install the transmission case plug assembly to the automatic transaxle assembly.

  4. INSTALL WIRE HARNESS CLAMP BRACKET


    1. Install the 4 wire harness clamp brackets to the automatic transaxle assembly with the 4 bolts.

      Torque:
      8.0 N*m  { 82 kgf*cm, 70 in.*lbf }

  5. INSTALL NO. 1 TRANSMISSION CONTROL CABLE BRACKET


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

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

  6. INSTALL TRANSMISSION BREATHER SKIRT


    1. Install the clamp to the transmission breather skirt.

    2. Install the transmission breather skirt to the transaxle with the bolt.

      Torque:
      20 N*m  { 204 kgf*cm, 15 ft.*lbf }

    3. Install the breather plug hose to the transmission breather skirt.

  7. INSTALL FRONT ENGINE MOUNTING BRACKET


    1. Install the front engine mounting bracket to the automatic transaxle assembly with the 3 bolts.

      Torque:
      64 N*m  { 653 kgf*cm, 47 ft.*lbf }

  8. INSTALL AUTOMATIC TRANSAXLE ASSEMBLY


    1. B000LZFE03
      Text in Illustration
      *1 Torque Converter Centerpiece
      *2 Crankshaft

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

      Clutch spline grease
      Toyota Genuine Clutch Spline Grease or equivalent
      Maximum grease amount
      Approximately 1 g (0.0353 oz.)
    2. B000JDZE01

      While keeping the engine and automatic transaxle assembly horizontal, align the knock pins with the holes in the automatic transaxle assembly and install the 9 bolts shown in the illustration.

      Bolt Bolt Length Torque
      A 55 mm (2.17 in.) 64 N*m (653 kgf*cm, 47 ft.*lbf)
      B 50 mm (1.97 in.) 46 N*m (469 kgf*cm, 34 ft.*lbf)
      C 32 mm (1.26 in.) 44 N*m (449 kgf*cm, 32 ft.*lbf)
      33 mm (1.30 in.) 43 N*m (438 kgf*cm, 32 ft.*lbf)

      Note


      • Confirm that the 2 knock pins are installed to the transaxle contact surface of the engine cylinder block before installing the automatic transaxle assembly.

      • Do not forcibly pry on the automatic transaxle assembly.

      • Check that the torque converter rotates.

  9. INSTALL WIRE HARNESS


    1. Connect the 7 wire harness clamps and park/neutral position switch connector.

    2. Install the ground cable with the bolt.

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

  10. INSTALL WIRING HARNESS CONNECTOR


    1. Install the wiring harness connector to the automatic transaxle assembly.

    2. B000NFPE01

      Install and tighten the 2 bolts in the order shown in the illustration.

      Torque:
      11 N*m  { 115 kgf*cm, 8 ft.*lbf }
    3. B000N0O

      Connect the connector to the wiring harness connector.

    4. Turn the lock lever and secure the connector with the lock lever.

  11. INSTALL FRONT FRAME ASSEMBLY


    1. Install the engine mounting insulator LH with the nut.

      Torque:
      95 N*m  { 969 kgf*cm, 70 ft.*lbf }

    2. Install the engine mounting insulator RH with the nut.

      Torque:
      95 N*m  { 969 kgf*cm, 70 ft.*lbf }

    3. Install the front engine mounting insulator with the bolt.

      Torque:
      87 N*m  { 887 kgf*cm, 64 ft.*lbf }

    4. Fully tighten the 9 temporarily installed nuts of the engine mounting insulators to the specified torque.

      B000M7GE04
      Text in Illustration
      *a Front Engine Mounting Insulator *b Engine Mounting Insulator RH
      *c Engine Mounting Insulator LH - -

      Tech Tips

      Perform this procedure only when replacement of the engine mounting insulator is necessary.

      Torque:
      A
      58 N*m  { 591 kgf*cm, 43 ft.*lbf }
      B
      99 N*m  { 1010 kgf*cm, 73 ft.*lbf }

    5. Install the 4 hole plugs.

      B000J2XE01
      Text in Illustration
      *a Engine Mounting Insulator RH *b Engine Mounting Insulator LH

      Tech Tips

      Perform this procedure only when replacement of the engine mounting insulator is necessary.

  12. INSTALL FRONT DRIVE SHAFT HOLE SNAP RING LH


    1. Install a new front drive shaft hole snap ring LH.

      Note

      Face the end gap of the front drive shaft hole snap ring downward.

  13. INSTALL FRONT DRIVE SHAFT ASSEMBLY LH


    1. Coat the spline of the front drive inboard joint assembly with ATF WS.

    2. Coat the lip of the transaxle case oil seal with MP grease.

    3. B000L2X

      Align the inboard joint splines, and using a brass bar and a hammer, install the front drive shaft assembly LH.

      Note


      • Face the end gap of the front drive shaft hole snap ring LH downward.

      • Do not damage the transaxle case oil seal.

      • Do not damage the front axle inboard joint boot.

      • Make sure to center the front drive shaft assembly LH during installation to prevent damage to the front drive shaft hole snap ring LH.

      Tech Tips

      Confirm whether the drive shaft is securely driven in by checking the reaction force and sound.

    4. for TMMK Made:


      1. B000J1B

        Apply mineral oil base grease to the areas indicated by the arrows in the illustration on the front drive shaft assembly LH contact surface of the front axle hub bearing.

        Text in Illustration
        B000JL5 Mineral Oil Base Grease

        Tech Tips

        Apply 0.1 to 0.3 g (0.00353 to 0.0106 oz.) of mineral oil base grease to each area.

    5. B000KZYE01
      Text in Illustration
      *a Matchmark

      Align the matchmarks and install the front drive shaft assembly LH to the front axle hub sub-assembly.

      Note

      Be careful not to damage the front axle outboard joint boot or speed sensor rotor.

  14. INSTALL FRONT DRIVE SHAFT ASSEMBLY RH


    1. Coat the spline of the front drive inboard joint assembly with ATF WS.

    2. Coat the lip of the front transaxle case oil seal with MP grease.

    3. Install a new bearing bracket hole snap ring to the front drive shaft assembly RH.

    4. Install the front drive shaft assembly RH.

      Note


      • Do not damage the front transaxle case oil seal.

      • Do not damage the front axle inboard joint boot.

      • When inserting the front drive shaft assembly RH, keep it level.

    5. B000JWY

      Install the bearing bracket hole snap ring and a new bolt.

      Torque:
      32 N*m  { 330 kgf*cm, 24 ft.*lbf }

    6. for TMMK Made:


      1. B000N73

        Apply mineral oil base grease to the areas indicated by the arrows in the illustration on the front drive shaft assembly RH contact surface of the front axle hub bearing.

        Text in Illustration
        B000JL5 Mineral Oil Base Grease

        Tech Tips

        Apply 0.1 to 0.3 g (0.00353 to 0.0106 oz.) of mineral oil base grease to each area.

    7. B000MBUE01
      Text in Illustration
      *a Matchmark

      Align the matchmarks and install the front drive shaft assembly RH to the front axle hub sub-assembly.

      Note

      Be careful not to damage the front axle outboard joint boot or speed sensor rotor.

  15. INSTALL ENGINE ASSEMBLY WITH TRANSAXLE

    Click here

  16. CHECK AUTOMATIC TRANSAXLE SYSTEM

    Note

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