AUTOMATIC TRANSMISSION ASSEMBLY (for 1KD-FTV) INSTALLATION


  1. INSTALL TORQUE CONVERTER ASSEMBLY


    1. A00O8H5E01
      Text in Illustration
      *1 Engine Surface
      *2 Drive Plate Surface

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

    2. A00O4G5E01
      Text in Illustration
      *1 Matchmark

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

    3. A00O700E01
      Text in Illustration
      *1 Matchmark

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

      Tech Tips

      Turn the torque converter approximately 180°.

    4. A00O5ICE01
      Text in Illustration
      *1 Matchmark

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

      Note

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

    5. A00O9XEE01

      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 control cable bracket with the 2 bolts.

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

  3. INSTALL TRANSFER ASSEMBLY

    Click here

  4. INSTALL WIRING HARNESS CLAMP BRACKET (w/ DPF)


    1. Install the wiring harness clamp bracket with the bolt.

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

  5. INSTALL NO. 1 SENSOR BRACKET (w/ DPF)


    1. Install the No. 1 sensor bracket with the bolt and nut.

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

    2. Attach the transfer breather hose clamp.

  6. INSTALL AUTOMATIC TRANSMISSION ASSEMBLY

    A00O6YYE02

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

      Clutch spline grease
      Toyota Genuine Clutch Spline Grease or equivalent
      Maximum grease amount
      Approximately 1 g (0.353 oz.)
      Text in Illustration
      *1 Torque Converter Centerpiece
      *2 Crankshaft
    2. A00O5IK

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

      Note


      • Insert the knock pins into the knock pin holes securely so that the end face of the transaxle assembly fits close against the engine assembly before tightening the bolts.

      • Do not use excess force to pry on the transmission assembly.

  7. CONNECT WIRE HARNESS AND CONNECTOR


    1. w/ DPF:


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

        A00OAFE

        Tech Tips

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

      2. Attach the 10 harness clamps.

    2. w/o DPF:


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

        A00O8QGE02

        Tech Tips

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

      2. Attach the 7 harness clamps.

    3. Tilt up the automatic transmission.

  8. INSTALL DRIVE PLATE AND TORQUE CONVERTER SETTING BOLT


    1. Turn the crankshaft to gain access to the installation locations of the 6 torque converter 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 }

      Tech Tips

      If it is difficult to reach the setting bolts with the wrench, raise or lower the transmission jack until there is sufficient space for the wrench.

      Note

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

  9. 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 }

  10. 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 }

  11. INSTALL FRONT SUSPENSION MEMBER BRACKET LH AND RH


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

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

  12. INSTALL OIL PAN INSULATOR


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

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

  13. INSTALL STARTER ASSEMBLY


    1. for 2.2 kW Type:

      Install the starter Click here.

    2. for 2.7 kW Type:

      Install the starter Click here.

    3. for 3.0 kW Type:

      Install the starter Click here.

  14. CONNECT NO. 1 INLET OIL COOLER TUBE AND NO. 1 OUTLET OIL COOLER TUBE

    A00O7A7E02

    1. Temporarily install the ends of the 2 oil cooler tubes to each oil cooler tube union by hand.

    2. Install the 3 oil cooler tube clamps with the 3 bolts.

      Torque:
      for bolt A
      5.5 N*m  { 56 kgf*cm, 49 in.*lbf }
      for bolt B
      14 N*m  { 143 kgf*cm, 10 ft.*lbf }

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

      Torque:
      34 N*m  { 347 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 PROPELLER SHAFT ASSEMBLY

    Click here

  17. INSTALL FRONT PROPELLER SHAFT ASSEMBLY

    Click here

  18. INSTALL FRONT EXHAUST PIPE ASSEMBLY

    w/ DPF: Click here

    w/o DPF: Click here

  19. INSTALL LOWER TRANSFER CASE PROTECTOR


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

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

  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. 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.

  23. 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.

  24. INSPECT FOR EXHAUST GAS LEAK


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

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


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

  26. INSTALL FRONT FENDER APRON SEAL RH


    1. Install the front fender apron seal RH with the 4 clips.

  27. 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 }

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


    1. Install the No. 1 engine under cover with the 4 bolts.

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

  29. PERFORM RESET MEMORY

    Click here