AUTOMATIC TRANSAXLE FLUID

PRECAUTIONS AND WORK DESCRIPTION

The U661F automatic transaxle assembly does not have an oil filler tube and oil level gauge. When adding fluid, add fluid through the refill hole on the rear transaxle cover sub-assembly. The fluid level can be adjusted by draining excess fluid (allowing excess fluid to overflow) through the No. 1 transmission oil filler tube of the automatic transaxle oil pan sub-assembly.

Tech Tips

"Overflow" indicates the condition under which fluid comes out of the overflow plug hole.
Before adjusting the fluid level, add the specified amount of fluid when the engine is cold and warm up the engine to circulate the fluid in the automatic transaxle assembly. Ensure that the fluid temperature is as specified and the engine is idling.
The U661E automatic transaxle assembly requires Toyota Genuine ATF WS.
The adjustment should be performed according to the procedures and notes.

WORK FLOW

The adjustment should be performed according to the procedure referenced in the work flow below.

PREPARATION WORK

w/ Air Cooled Transmission Oil Cooler:

Remove the front bumper cover.

for Sport Package:

Click here

except Sport Package:

Click here

*1	Transmission Oil Thermostat
*2	Cap
*3	Shaft
*4	Pin
*a	Screwdriver
*b	Step

Using compressed air, etc., blow dust off the cap to clean it.

Using a screwdriver, push the shaft of the transmission oil thermostat.
Tech Tips
- Pushed amount: 5.5 to 7.0 mm (0.217 to 0.275 in.)
- Push the shaft until the screwdriver contacts the step inside the cap.
With the shaft of the transmission oil thermostat pressed, push a pin into a hole on the side of the cap. Insert the pin until it passes through the hole on the other side of the cap to fix the shaft in place.

Tech Tips

Pin diameter: 1.0 to 1.8 mm (0.0394 to 0.0708 in.)

Lift the vehicle.

Note

Set the vehicle on a lift so that the vehicle is kept level when it is lifted up (make sure that the tilt angle from the front to rear of the vehicle is within +/-1°).
Remove the No. 1 engine under cover.

Click here
Remove the rear engine under cover LH.

Click here

PERFORM INITIAL FILLING

Note

If the automatic transaxle assembly is hot (ATF temperature is high), wait until the fluid temperature becomes the same as the ambient temperature before starting the following procedure. (Recommended ATF temperature: around 20°C [68°F])

Remove the refill plug and gasket from the automatic transaxle assembly.

Note

After performing any of the following operations, it is not necessary to perform the initial filling procedure. Proceed to the Add Specified Amount of Fluid procedure.

Operations that do not require initial filling
Disconnection of the oil cooler tube or oil cooler hose Repair of fluid leak due to a loose case plug, or a faulty plug gasket or O-ring

Using a 6 mm hexagon socket wrench, remove the overflow plug and gasket from the automatic transaxle oil pan sub-assembly.
Note
- If ATF comes out after removing the overflow plug, wait until the fluid flow slows and only drips come out.
- If ATF comes out, it is not necessary to perform the initial filling procedure. After checking the tightening torque of the No. 1 transmission oil filler tube, temporarily install the overflow plug.
*1 No. 1 Transmission Oil Filler Tube

Using a 6 mm hexagon socket wrench, check that the No. 1 transmission oil filler tube is tightened to the specified torque.

Torque:

1.7 N*m { 17 kgf*cm, 15 in.*lbf }

Note

If the No. 1 transmission oil filler tube is not tightened to the specified torque, the amount of fluid cannot be precisely adjusted.

Tech Tips

To check the torque of the No. 1 transmission oil filler tube, insert the hexagon socket wrench into the overflow plug hole.
Perform initial filling.
1. Fill the automatic transaxle assembly through the refill hole until fluid begins to come out of the overflow plug hole.
  
  Note
  
  Use Toyota Genuine ATF WS.
Wait until the fluid flow slows and only drips come out.
Temporarily install the gasket and the overflow plug to the automatic transaxle oil pan sub-assembly.

Tech Tips

Reuse the old gasket as the overflow plug will be removed again to adjust the fluid level.

ADD SPECIFIED AMOUNT OF FLUID

Fill the automatic transaxle assembly with the correct amount of fluid as listed in the table below.

Note

The refill amount differs depending on the operation that was performed.

Reference Capacity

Performed Repair	Fill Amount
Automatic transaxle assembly replacement (with a new torque converter assembly)	5.3 liters (5.6 US qts, 4.7 Imp.qts)
Automatic transaxle assembly replacement (when reusing the torque converter assembly)	3.4 liters (3.6 US qts, 3.0 Imp.qts)
Removal and installation of the torque converter assembly	4.8 liters (5.1 US qts, 4.2 Imp.qts)
Removal and installation of the transmission valve body assembly	3.2 liters (3.4 US qts, 2.8 Imp.qts)
Removal and installation of the automatic transaxle oil pan sub-assembly	2.8 liters (3.0 US qts, 2.5 Imp.qts)
Removal and installation of a front drive shaft assembly	2.8 liters (3.0 US qts, 2.5 Imp.qts)
Removal and installation of the front drive shaft oil seal LH or front drive shaft oil seal RH	2.8 liters (3.0 US qts, 2.5 Imp.qts)
Disconnection of an oil cooler tube or oil cooler hose	0.5 liters (0.5 US qts, 0.4 Imp.qts)
Repair of fluid leak due to a loose case plug, or a faulty plug gasket or O-ring	0.5 liters (0.5 US qts, 0.4 Imp.qts)

Temporarily install the gasket and refill plug to avoid fluid spillage.

Tech Tips

Reuse the old gasket as the refill plug will be removed again to adjust the fluid level.
Lower the vehicle.

BLEED AIR FROM OIL PUMP ASSEMBLY WITH MOTOR (w/ Stop And Start System)

ADJUST FLUID TEMPERATURE (when Using the GTS)

Tech Tips

The actual ATF temperature can be checked on the Data List using the GTS.

Connect the GTS to the DLC3 with the engine switch off.
Turn the engine switch to ON and turn the GTS on.

Note

To reduce load, make sure that all electrical systems, such as the air conditioning, lighting system, electric fans and audio system are off.
Enter the following menus: Powertrain / Transmission / Active Test / Activate the TC Terminal.

Powertrain > Transmission > Active Test

Tester Display

Activate the TC Terminal
Select the Active Test item: Activate the TC Terminal / ON.
Select the Data List menu: A/T Oil Temperature No. 1.

Powertrain > Transmission > Data List

Tester Display

A/T Oil Temperature No.1
Check the ATF temperature.
Note
- If the fluid temperature is below 45°C (113°F), proceed to the next step. (Recommended ATF temperature: 40°C (104°F) or less)
- If the fluid temperature is 45°C (113°F) or more, turn the engine switch to off and wait until the fluid temperature drops below 45°C (113°F).
Depress and hold the brake pedal.
Start the engine.
Slowly move the shift lever from P to D, and then back to P.

Tech Tips

Slowly move the shift lever to circulate the fluid through each part of the automatic transaxle assembly.
While observing the D shift indicator on the combination meter, move the shift lever back and forth between N and D at an interval of less than 1.5 seconds for 6 seconds or more.

Note

Do not pause for more than 1.5 seconds.

Tech Tips

Performing this operation will cause the vehicle to enter fluid temperature detection mode.
Check that the D shift indicator comes on for 2 seconds.
Tech Tips
- When fluid temperature detection mode is activated, the D shift indicator on the combination meter comes on for 2 seconds.
- If the D shift indicator does not come on for 2 seconds, return to the first step and perform the procedure again.
Move the shift lever from N to P.
Release the brake pedal.
Select the Active Test item: Activate the TC Terminal / OFF.

Note

Be sure that terminal TC is not connected. If the terminal is connected, the fluid level cannot be precisely adjusted due to fluctuations in engine speed.
Tech Tips
- Disconnecting terminal TC activate engine idle speed control mode.
- In engine idle speed control mode, engine idle speed control starts when the fluid temperature is 40°C (104°F) or more and the engine speed is maintained at approximately 800 rpm.
- Even after terminal TC is disconnected, fluid temperature detection mode is active until the engine switch is turned off.

Tester Display
Activate the TC Terminal

Tester Display
A/T Oil Temperature No.1

Warm up the engine with the engine idling until the fluid temperature reaches the fluid level adjustment temperature (40 to 45°C (104 to 113°F)).

Below Fluid Level Adjustment Temperature

Fluid Level Adjustment Temperature

Above Fluid Level Adjustment Temperature

40°C or less

(104°F or less)

40 to 45°C

(104 to 113°F)

45°C or more

(113°F or more)

Note

If the fluid temperature is within the fluid level adjustment temperature range, immediately proceed to the Adjust Fluid Level procedure.
If the fluid temperature is 45°C (113°F) or more, stop the engine and wait until the fluid temperature drops to 40°C (104°F) or less. Then perform the Adjust Fluid Temperature procedure again from the beginning.

Tech Tips

In fluid temperature detection mode, the D shift indicator comes on, goes off, or blinks depending on the fluid temperature.

D Shift Indicator
Below Fluid Level Adjustment Temperature (40°C or less) (104°F or less)	Fluid Level Adjustment Temperature (40 to 45°C) (104 to 113°F)	Above Fluid Level Adjustment Temperature (45°C or more) (113°F or more)
OFF	ON	Blinks

ADJUST FLUID TEMPERATURE (when Not Using the GTS)

*a DLC3

Using SST, connect terminals 13 (TC) and 4 (CG) of the DLC3 with the engine switch off.

SST

09843-18040
Depress and hold the brake pedal.
Start the engine.

Note

To reduce load, make sure that all electrical systems, such as the air conditioning, lighting system, electric fans and audio system, are off.

Tech Tips

The indicator lights on the combination meter blink to indicate the DTC output when terminals TC and CG are connected.
Slowly move the shift lever from P to D, and then back to P.

Tech Tips

Slowly move the shift lever to circulate the fluid through each part of the transaxle.
While observing the D shift indicator on the combination meter, move the shift lever back and forth between N and D at an interval of less than 1.5 seconds for 6 seconds or more.

Note

Do not pause for more than 1.5 seconds.

Tech Tips

Performing this operation will cause the vehicle to enter fluid temperature detection mode.
Check that the D shift indicator comes on for 2 seconds.
Tech Tips
- When fluid temperature detection mode is activated, the D shift indicator on the combination meter comes on for 2 seconds.
- If the D shift indicator does not come on for 2 seconds, return to the first step and perform the procedure again.
Move the shift lever from N to P.
Release the brake pedal.
*a DLC3

Remove SST from terminals 13 (TC) and 4 (CG).

SST

09843-18040

Note

Be sure that terminals TC and CG are not connected. If the terminals are connected, the fluid level cannot be precisely adjusted due to fluctuations in engine speed.
Tech Tips
- Disconnecting terminals TC and CG activates engine idle speed control mode.
- In engine idle speed control mode, engine idle speed control starts when the fluid temperature is 40°C (104°F) or more and the engine speed is maintained at approximately 800 rpm.
- Even after terminals TC and CG are disconnected, fluid temperature detection mode is active until the engine switch is turned off.

Allow the engine to idle until the D shift indicator comes on again.

D Shift Indicator
Below Fluid Level Adjustment Temperature (40°C or less) (104°F or less)	Fluid Level Adjustment Temperature (40 to 45°C) (104 to 113°F)	Above Fluid Level Adjustment Temperature (45°C or more) (113°F or more)
OFF	ON	Blinks

Note

If the D shift indicator is on, immediately proceed to the Adjust Fluid Level procedure.
If the D shift indicator blinks, stop the engine and wait until the fluid temperature drops to 40°C (104°F) or less (the indicator goes off). Then perform the Adjust Fluid Temperature procedure again from the beginning.

Tech Tips

In fluid temperature detection mode, the D shift indicator comes on, goes off, or blinks depending on the fluid temperature.
The fluid filling procedure should be performed when the D shift indicator is on (the fluid temperature is within the fluid level adjustment temperature range).

ADJUST FLUID LEVEL

CAUTION:

Use caution while the engine is idling and the radiator fans are operating.

Lift the vehicle.

Note

Set the vehicle on a lift so that the vehicle is kept level when it is lifted up (make sure the tilt angle from the front to rear of the vehicle is within +/-1°).
Adjust the fluid level.
1. Using a 6 mm hexagon socket wrench, remove the overflow plug and gasket from the automatic transaxle oil pan sub-assembly.
  
  CAUTION:
  
  Be careful as the fluid coming out of the overflow plug hole is hot.
2. Check the amount of fluid that comes out of the overflow plug hole.
  
  Note
  
  If only a small amount of fluid (approximately 1 cc) comes out of the overflow plug hole, then only fluid remaining in the No. 1 transmission oil filler tube has come out. This condition is not considered as overflow, so it is necessary to add fluid.
3. If the amount of fluid that comes out of the overflow plug hole is large, wait until the fluid flow slows and only drips come out.
4. If no fluid comes out of the overflow plug hole, remove the refill plug and gasket. Then add transaxle fluid through the refill hole until fluid comes out of the overflow plug hole. Wait until the fluid flow slows and only drips come out.
  
  Note
  
  Use Toyota Genuine ATF WS.
5. Check that the fluid flow has slowed and only drips come out.
  
  Tech Tips
  
  The fluid flow will not completely stop because the fluid continues to expand as its temperature increases.
Using a 6 mm hexagon socket wrench, install a new gasket and the overflow plug to the automatic transaxle oil pan sub-assembly.

Torque:

40 N*m { 408 kgf*cm, 30 ft.*lbf }
Install a new gasket and the refill plug to the automatic transaxle assembly.

Torque:

49 N*m { 500 kgf*cm, 36 ft.*lbf }
Lower the vehicle.
Turn the engine switch off.

Tech Tips

Turning the engine switch off ends fluid temperature detection mode.
Disconnect the GTS from the DLC3 (when Using the GTS).

REBUILD WORK

Lift the vehicle.
Clean each part.
Check for fluid leaks.
Install the rear engine under cover LH.

Click here
Install the No. 1 engine under cover.

Click here
Lower the vehicle.

w/ Air Cooled Transmission Oil Cooler:

*1	Transmission Oil Thermostat
*2	Cap
*3	Shaft
*4	Pin
*a	Screwdriver

Remove the pin by pushing the shaft with a screwdriver.

Note

Make sure the shaft of the transmission oil thermostat is protruding from the hole on the cap.

Install the front bumper cover.

for Sport Package:

Click here

except Sport Package:

Click here

AUTOMATIC TRANSAXLE FLUID ADJUSTMENT