AUTOMATIC TRANSMISSION ASSEMBLY (for 1GR-FE) INSTALLATION


  1. INSPECT TORQUE CONVERTER CLUTCH ASSEMBLY


    1. Inspect the torque converter clutch assembly Click here.

  2. INSTALL TORQUE CONVERTER CLUTCH ASSEMBLY


    1. Install the torque converter clutch to the automatic transmission.

    2. A01DX98E01

      Using a vernier caliper and straightedge, measure dimension A between the surface of the engine that contacts the transmission*1, and the surface of the drive plate that contacts the converter*2. (#)

    3. A01E19JE01

      Using a vernier caliper and straightedge, measure dimension B shown in the illustration. Check that B is greater than A measured in step #.

      Standard
      B = A + 1.00 mm (0.0394 in.) or more

  3. INSTALL TRANSFER ASSEMBLY


    1. Install the transfer assembly Click here.

  4. INSTALL AUTOMATIC TRANSMISSION ASSEMBLY

    A01E32NE01

    1. 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 1.0 g (0.0353 oz)
    2. A01DWDCE01

      Install the transmission to the engine with the 9 bolts.

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

      Note

      Confirm that the 2 knock pins are installed to the surface of the engine block before installing the transmission..

    3. A01DYVG

      Hold the crankshaft pulley bolt with a wrench and install the 6 torque converter clutch setting bolts.

      Torque:
      48 N*m  { 489 kgf*cm, 35 ft.*lbf }

      Tech Tips

      First install the black bolt, and then the other 5 bolts.

  5. INSTALL FLYWHEEL HOUSING SIDE COVER


    1. Install the flywheel housing side cover to the cylinder block.

  6. INSTALL STARTER ASSEMBLY


    1. for 1.4 kW Type:

      Install the starter assembly Click here.

    2. for 1.6 kW Type:

      Install the starter assembly Click here.

  7. CONNECT WIRE HARNESS


    1. Connect the park/neutral position switch connector.

    2. Connect the transmission wire connector.

    3. Connect the 2 speed sensor connectors.

    4. Connect the No. 1 indicator switch connector.

    5. Connect the No. 2 indicator switch connector.

    6. Connect the No. 3 indicator switch connector.

    7. Connect the speed sensor connector.

    8. Attach the 7 wire harness clamps.

    9. Connect the ground cable with the nut.

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

  8. INSTALL REAR NO. 1 ENGINE MOUNTING INSULATOR

    A01DVPCE01

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

      Torque:
      47 N*m  { 479 kgf*cm, 35 ft.*lbf }

  9. INSTALL NO. 3 FRAME CROSSMEMBER SUB-ASSEMBLY

    A01E2RRE03

    1. Install the frame crossmember to the rear No. 1 engine mounting insulator with the 4 set bolts.

      Torque:
      17 N*m  { 173 kgf*cm, 13 ft.*lbf }

    2. Connect the ends of the frame crossmember to the vehicle with the 4 bolts and 4 nuts.

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

  10. INSTALL NO. 1 TRANSMISSION CONTROL CABLE BRACKET

    A01DV19

    1. Install the control cable bracket with the 2 bolts.

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

  11. INSTALL TRANSMISSION CONTROL CABLE ASSEMBLY

    A01DX06

    1. Connect the control cable with a new clip.

    2. Connect the control cable with the nut.

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

  12. INSTALL OIL COOLER TUBE

    A01E0HP

    1. Loosely install the tip of the inlet oil cooler tube to the automatic transmission by hand.

    2. Loosely install the tip of the outlet oil cooler tube to the automatic transmission by hand.

    3. Install the 2 clamps with the 2 bolts.

      Torque:
      5.0 N*m  { 50 kgf*cm, 43 in.*lbf }
    4. A01E06ZE01

      Using a union nut wrench, tighten the inlet and outlet oil cooler 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.

  13. INSTALL EXHAUST MANIFOLD SUB-ASSEMBLY RH


    1. A01E2YSE02

      Set a new gasket to the RH cylinder head with the oval shape facing forward.

      Note

      Be careful of the installation direction.

    2. Install the exhaust manifold with the 6 nuts. Uniformly tighten the nuts in several passes.

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

    3. Connect the A/F sensor connector.

  14. INSTALL EXHAUST MANIFOLD SUB-ASSEMBLY LH


    1. A01DXK6E01

      Set a new gasket to the LH cylinder head with the oval shape facing backward.

      Note

      Be careful of the installation direction.

    2. Install the exhaust manifold with the 6 nuts. Uniformly tighten the nuts in several passes.

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

    3. Connect the A/F sensor connector.

  15. INSTALL NO. 2 MANIFOLD STAY

    A01DX7WE01

    1. Install the manifold stay with the 3 bolts.

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

  16. INSTALL MANIFOLD STAY

    A01DZ6QE01

    1. Install the manifold stay with the 3 bolts.

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

  17. INSTALL PROPELLER SHAFT WITH CENTER BEARING ASSEMBLY


    1. for TSAM Made:

      Install the propeller shaft with center bearing assembly Click here.

    2. for TMT Made:

      Install the propeller shaft with center bearing assembly Click here.

  18. INSTALL FRONT PROPELLER SHAFT ASSEMBLY


    1. for TSAM Made:

      Install the front propeller shaft assembly Click here.

    2. for TMT Made:

      Install the front propeller shaft assembly Click here.

  19. INSTALL EXHAUST PIPE


    1. Install the exhaust pipe Click here.

  20. CONNECT HEATED OXYGEN SENSOR


    1. Connect the 2 sensor connectors.

  21. INSTALL TRANSFER HIGH AND LOW SHIFT LEVER ASSEMBLY


    1. A01E2ANE02

      While pushing the select return spring to the left with the end of the transfer high and low shift lever, insert the end of the shift lever into the shift fork.

    2. A01DXRLE03

      While holding down the shift lever cap, install the snap ring to install the transfer high and low shift lever.

    3. Return the transfer front drive shift boot to its original position.

  22. INSTALL SHIFT LEVER BOOT ASSEMBLY


    1. Install the shift lever boot with the 4 screws.

  23. INSTALL CONSOLE BOX ASSEMBLY

    A01E1MRE01
    Text in Illustration
    *1 Screw
    *2 Bolt
    *3 Clip

    1. Install the console box with the 4 screws and 2 bolts.

    2. Install the 2 clips.

  24. INSTALL UPPER CONSOLE PANEL SUB-ASSEMBLY


    1. Attach the 12 claws to install the upper console panel.

      A01DZBTE01
      Text in Illustration
      *A for 2WD *B for 4WD

  25. INSTALL PARKING BRAKE HOLE COVER SUB-ASSEMBLY


    1. Attach the 4 claws to install the parking brake hole cover.

  26. INSTALL SHIFT LEVER KNOB SUB-ASSEMBLY

    A01E2OH

    1. Install the shift lever knob and twist it in the direction indicated by the arrow.

  27. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

    Note

    Certain systems need to be initialized after disconnecting and reconnecting the cable to the negative (-) battery terminal.

  28. ADD AUTOMATIC TRANSMISSION FLUID


    1. Add automatic transmission fluid Click here.

  29. 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 the shift lever moves smoothly and correctly into position.

    2. 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 shifting to R.

      If the results are not as specified, inspect the park/ neutral position switch and check the shift lever.

  30. PERFORM INITIALIZATION


    1. Perform initialization Click here.

  31. CHECK FOR EXHAUST GAS LEAKS

  32. INSTALL NO. 3 ENGINE UNDER COVER

    Torque:
    28 N*m  { 285 kgf*cm, 21 ft.*lbf }

  33. INSTALL NO. 2 ENGINE UNDER COVER

    Torque:
    28 N*m  { 285 kgf*cm, 21 ft.*lbf }

  34. INSTALL NO. 1 ENGINE UNDER COVER

    Torque:
    28 N*m  { 285 kgf*cm, 21 ft.*lbf }