AUTOMATIC TRANSMISSION ASSEMBLY (for 1GR-FE) INSTALLATION


  1. INSTALL TORQUE CONVERTER CLUTCH ASSEMBLY


    1. A00O8AKE01

      Using a vernier caliper and straightedge, measure dimension" A" between the transmission fitting surface of the engine *1 and the torque converter fitting surface of the drive plate *2 (step 1).

    2. A00O5QAE05
      Text in Illustration
      *1 Matchmark

      Align the matchmarks on the transmission case and torque converter clutch, and then mesh the splines of the input shaft and turbine runner.

    3. A00O9PGE04
      Text in Illustration
      *1 Matchmark

      Mesh the splines of the stator shaft and stator while turning the torque converter clutch.

      Tech Tips

      Turn the torque converter clutch approximately 180°.

    4. A00O861E02
      Text in Illustration
      *1 Matchmark

      Turn the torque converter clutch and align the matchmarks on the torque converter clutch and transmission case to fit the key of the oil pump drive gear into the slot on the torque converter clutch.

      Note

      Do not push on the torque converter when aligning the matchmarks.

    5. A00O77ME01

      Using a vernier caliper and straightedge, measure dimension B shown in the illustration and check that B is more than A, which was measured in the first step.

      Standard distance
      B = A + 1 mm (0.0394 in.) or more

  2. INSTALL NO. 1 TRANSMISSION CONTROL CABLE BRACKET


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

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

  3. INSTALL TRANSFER ASSEMBLY


    1. Install the transfer Click here.

  4. INSTALL AUTOMATIC TRANSMISSION ASSEMBLY


    1. A00O5LLE01
      Text in Illustration
      *1 Torque Converter Clutch Centerpiece
      *2 Crankshaft

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

      Clutch spline grease
      Toyota Genuine Clutch Spline Grease or equivalent
      Maximum grease amount
      Approximately 1 g (0.0353 oz.)
    2. A00OBIBE01

      Confirm that the 2 knock pins are on the transmission contact surface of the engine block before transmission installation.

    3. Install the transmission with the 9 bolts.

      Torque:
      for 17 mm head bolt A
      71 N*m  { 724 kgf*cm, 52 ft.*lbf }
      for 14 mm head bolt B
      37 N*m  { 377 kgf*cm, 27 ft.*lbf }

  5. CONNECT BREATHER HOSE


    1. Connect the 3 breather plug hoses to the engine.

  6. CONNECT WIRE HARNESS AND CONNECTOR


    1. Connect the park/neutral position switch connector, transmission wire connector, 2 speed sensor connectors and transfer control side connector.

      Tech Tips

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

    2. Attach the 2 connector clamps and 7 harness clamps.

      A00O5D0E02

    3. Tilt up the automatic transmission.

    4. Connect the ground cable with the nut.

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

  7. INSTALL REAR NO. 1 ENGINE MOUNTING INSULATOR


    1. Install the rear engine mounting insulator to the transmission with the 4 bolts.

      Torque:
      65 N*m  { 663 kgf*cm, 48 ft.*lbf }

    2. Install the rear engine mounting heat insulator to the engine mounting insulator with the bolt.

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

  8. INSTALL NO. 3 FRAME CROSSMEMBER SUB-ASSEMBLY


    1. Install the frame crossmember to the rear engine mounting insulator with the 4 bolts.

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

    2. Install the frame crossmember with the 4 bolts and 4 nuts.

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

  9. 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 }

  10. INSTALL DRIVE PLATE AND TORQUE CONVERTER CLUTCH SETTING BOLT


    1. A00OB11

      Turn the crankshaft to gain access to the installation locations of the 6 torque converter clutch 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 bolt first, and then the 5 silver bolts.

    2. Install the flywheel housing side cover.

  11. INSTALL STARTER ASSEMBLY


    1. Install the starter Click here.

  12. CONNECT NO. 1 INLET OIL COOLER TUBE AND NO. 1 OUTLET OIL COOLER TUBE (w/o Air Cooled Transmission Oil Cooler)

    A00OAYM

    1. Install the 2 oil cooler tubes with the 2 bolts.

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

  13. INSTALL TRANSMISSION OIL COOLER ASSEMBLY (w/o Air Cooled Transmission Oil Cooler)


    1. A00O780E02

      Connect the 2 hoses to the oil cooler tube unions.

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

      Torque:
      21 N*m  { 214 kgf*cm, 15 ft.*lbf }
    3. A00O7M1

      Connect the No. 2 oil cooler inlet hose and No. 2 oil cooler outlet hose to the transmission oil thermostat.

      Note

      Make sure the pinching portion of each clip are facing the directions shown in the illustration.

    4. A00OAL3E03
      Text in Illustration
      *1 White Paint Mark
      *2 Yellow Paint Mark

      Connect the 2 water by-pass hoses and install the water by-pass pipe to the automatic transmission with the 2 bolts.

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

      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.

  14. CONNECT NO. 1 INLET OIL COOLER TUBE AND NO. 1 OUTLET OIL COOLER TUBE (w/ Air Cooled Transmission Oil Cooler)


    1. Temporarily install the ends of the oil cooler inlet tube and outlet tube to each oil cooler tube union by hand.

    2. Close the 2 No. 2 flexible hose clamps and install the 2 bolts.

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

    3. Using a union nut wrench, tighten the inlet and outlet tubes.

      Torque:
      34 N*m  { 346 kgf*cm, 25 ft.*lbf }

      Note

      Use the formula to calculate special torque values for situations where a union nut wrench is combined with a torque wrench Click here.

  15. CONNECT TRANSMISSION CONTROL CABLE ASSEMBLY


    1. Connect the transmission control cable to the transmission control cable bracket with a new clip, and then connect the cable end to the control shaft lever with the nut.

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

  16. INSTALL MANIFOLD STAY


    1. Install the stay with the 3 bolts.

      Torque:
      40 N*m  { 408 kgf*cm, 30 ft.*lbf }

  17. INSTALL NO. 2 MANIFOLD STAY


    1. Install the stay with the 3 bolts.

      Torque:
      40 N*m  { 408 kgf*cm, 30 ft.*lbf }

  18. INSTALL PROPELLER SHAFT ASSEMBLY


    1. Install the propeller shaft Click here.

  19. INSTALL FRONT PROPELLER SHAFT ASSEMBLY


    1. Install the front propeller shaft Click here.

  20. INSTALL FRONT EXHAUST PIPE ASSEMBLY


    1. Install the front exhaust pipe Click here.

  21. INSTALL TRANSFER CASE LOWER PROTECTOR


    1. Install the transfer case lower protector with the 4 bolts.

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

  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. ADD ENGINE COOLANT


    1. Tighten the cylinder block drain cock plug.

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

    2. Tighten the radiator drain cock plug by hand.

    3. Add engine coolant.

      Standard Capacity
      Item Specified Condition
      for Automatic Transmission w/o Warmer w/o Rear Heater 10.5 liters (11.1 US qts, 9.2 Imp. qts)
      w/ Rear Heater 12.3 liters (13.0 US qts, 10.8 Imp. qts)
      w/ Warmer w/o Rear Heater 11.0 liters (11.6 US qts, 9.7 Imp. qts)
      w/ Rear Heater 12.8 liters (13.5 US qts, 11.3 Imp. qts)
      for Manual Transmission w/o Rear Heater 10.7 liters (11.3 US qts, 9.4 Imp. qts)
      w/ Rear Heater 12.5 liters (13.2 US qts, 11.0 Imp. qts)

      Note

      Do not substitute plain water for engine coolant.

      Tech Tips


      • TOYOTA vehicles are filled with TOYOTA SLLC at the factory. In order to avoid damage to the engine cooling system and other technical problems, only use TOYOTA SLLC or similar high quality ethylene glycol based non-silicate, non-amine, non-nitrite, non-borate coolant with long-life hybrid organic acid technology (coolant with long-life hybrid organic acid technology consists of a combination of low phosphates and organic acids).

      • Press the No. 1 and No. 2 radiator hoses several times by hand, and then check the coolant level. If the coolant level is low, add coolant.

    4. Slowly pour coolant into the radiator reservoir until it reaches the F line.

    5. Install the reservoir cap.

    6. Install the radiator cap.*1

    7. Start the engine and stop it immediately.*2

    8. Allow approximately 10 seconds to pass. Then remove the radiator cap and check the coolant level. If the coolant level has decreased, add coolant.*3

    9. Repeat steps *1, *2 and *3 until the coolant level does not decrease.

      Tech Tips

      Be sure to perform this step while the engine is cold, as air in the No. 1 radiator hose will flow into the radiator if the engine is warmed up and the thermostat opens.

    10. Install the radiator cap.*4

    11. Set the air conditioning as follows.*5

      Item Condition
      Fan speed Any setting except off
      Temperature Toward WARM
      Air conditioning switch Off

    12. Start the engine, warm it up until the thermostat opens, and then continue to run the engine for several minutes to circulate the coolant.*6

      CAUTION:


      • Wear protective gloves. Hot areas on the parts may injure your hands.

      • Be careful of the fan.

      • Be careful as the engine, radiator and radiator hoses are hot and can cause burns.

      Note


      • Immediately after starting the engine, if the radiator reservoir does not have any coolant, perform the following: 1) stop the engine, 2) wait until the coolant has cooled down, and 3) add coolant until the coolant is filled to the F line.

      • Do not start the engine when there is no coolant in the radiator reservoir.

      • Pay attention to the needle of the engine coolant temperature receiver gauge. Make sure that the needle does not show an abnormally high temperature.

      • If there is not enough coolant, the engine may burn out or overheat.

      Tech Tips


      • Press the No. 1 and No. 2 radiator hoses several times by hand to bleed air while warming up the engine.

      • The thermostat opening timing can be confirmed by pressing the No. 2 radiator hose by hand and checking when the engine coolant starts to flow inside the hose.

    13. Stop the engine, wait until the engine coolant cools down to ambient temperature. Then remove the radiator cap and check the coolant level.*7

      CAUTION:

      Do not remove the radiator cap while the engine and radiator are still hot. Pressurized, hot engine coolant and steam may be released and cause serious burns.

    14. If the coolant level has decreased, add coolant and warm up the engine until the thermostat opens.*8

    15. If the coolant level has not decreased, check that the coolant level in the radiator reservoir is at the F line.

      If the coolant level is below the F line, repeat steps *4 through *8.

      If the coolant level is above the F line, drain coolant until the coolant level reaches the F line.

  24. ADD AUTOMATIC TRANSMISSION FLUID


    1. Add automatic transmission fluid Click here.

  25. INSPECT FOR COOLANT LEAK

    CAUTION:

    To avoid being burned, do not remove the radiator reservoir cap while the engine and radiator are still hot. Thermal expansion may cause hot engine coolant and steam to blow out from the radiator.


    1. Fill the radiator with engine coolant, and then attach a radiator cap tester.

    2. Warm up the engine.

    3. Using the radiator cap tester, increase the pressure inside the radiator to 123 kPa (1.3 kgf/cm2, 18 psi), and then check that the pressure does not drop.

      If the pressure drops, check the hoses, radiator and water pump for leakage. If there are no signs or traces of external engine coolant leakage, check the heater core, cylinder block and head.

  26. INSPECT SHIFT LEVER POSITION


    1. When moving the shift lever from P to R with the ignition switch ON 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 in reverse after moving the shift lever to R.

      If the operation cannot be performed as specified, inspect the park/neutral position switch assembly and check the transmission floor shift assembly installation condition.

  27. ADJUST SHIFT LEVER POSITION


    1. Remove the rear console box Click here.

    2. w/ Refrigerated Cool Box:

      Remove the console box Click here.

    3. Move the shift lever to N.

    4. A00O94DE01
      Text in Illustration
      *1 Slider
      *2 Lock Piece

      Slide the slider in the direction shown in the illustration and pull out the lock piece.

    5. A00OAN9E04

      Push the lock piece into the adjuster case and lock it.

      Note

      Make sure that the lock piece is completely locked by the slider.

    6. Install the rear console box Click here.

    7. w/ Refrigerated Cool Box:

      Install the console box Click here.

  28. INSPECT FOR EXHAUST GAS LEAK


    • If gas is leaking, tighten the areas necessary to stop the leak. Replace damaged parts as necessary.

  29. INSTALL FRONT NO. 1 FENDER APRON TO FRAME SEAL RH


    1. Install the front No. 1 fender apron to frame seal with the 5 clips.

  30. INSTALL FRONT FENDER APRON SEAL RH


    1. Install the front fender apron seal with the 5 clips.

  31. INSTALL REAR ENGINE UNDER COVER ASSEMBLY


    1. Install the rear engine under cover with the 4 bolts.

      Torque:
      29 N*m  { 296 kgf*cm, 21 ft.*lbf }

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


    1. A00XIZZ

      Hook the engine under cover to the vehicle body as shown in the illustration.

    2. Install the 4 bolts.

      Torque:
      29 N*m  { 296 kgf*cm, 21 ft.*lbf }

  33. PERFORM RESET MEMORY


    1. Perform the Reset Memory procedures (A/T initialization) Click here.