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Automatic Transmission Assembly: Installation

  1. INSTALL TORQUE CONVERTER CLUTCH ASSEMBLY 
    1. Using a vernier caliper and straightedge, measure dimension A between the transmission and the end surface of the drive plate.
    2. Install the torque converter to the transmission housing.
      Fig 1: Measuring Dimension A Between Transmission And End Surface Of Drive Plate
      G05629228Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Using a vernier caliper and straightedge, measure dimension B shown in the illustration (Fig 2) and check that B is more than A measured in the first step.

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

  2. INSTALL WIRE HARNESS CLAMP BRACKET 
    1. Install the front bracket LH with the bolt.

      Torque: 8.0 N*m (82 kgf*cm, 71 in.*lbf) 

    2. Install the rear bracket LH with the bolt.

      Torque: 29 N*m (296 kgf*cm, 21 ft.*lbf) 

    3. Install the rear bracket RH with the bolt.

      Torque: 29 N*m (296 kgf*cm, 21 ft.*lbf) 

      Fig 2: Measuring Dimension B
      G05629229Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Install the front bracket RH with the bolt.

      Torque: 8.0 N*m (82 kgf*cm, 71 in.*lbf) 

    5. Install the rear engine bracket with the bolt.

      Torque: 8.0 N*m (82 kgf*cm, 71 in.*lbf) 

  3. INSTALL TRANSFER ASSEMBLY 
    1. Install the transfer with the 8 bolts.

      Torque: 40 N*m (408 kgf*cm, 30 ft.*lbf) 

      NOTE: Be careful not to damage the oil seal of the transfer adapter.
      Fig 3: Locating Transfer Assembly Bolts
      G05629230Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the transfer case lower protector with the 7 bolts.

      Torque: 14 N*m (143 kgf*cm, 10 ft.*lbf) 

    3. Connect the clamp of grand cable to the transfer case lower protector.
      Fig 4: Locating Transfer Case Lower Protector Bolts
      G05629231Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Attach the 3 breather hose clamps to connect the transfer breather hose to the automatic transmission breather tube.
      Fig 5: Locating Breather Hose Clamps
      G05629232Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  4. CONNECT BREATHER PLUG HOSE 
    1. Connect the 2 breather plug hoses to the harness clamp bracket.
      Fig 6: Locating Breather Plug Hoses Harness Clamp Bracket
      G05629233Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  5. INSTALL TRANSMISSION OIL COOLER ASSEMBLY 
    1. Coat 4 new O-rings with ATF.
    2. Install the 4 O-rings, transmission oil thermostat and transmission oil cooler to the automatic transmission.
    3. Temporarily install bolt A. Install the bolts labeled B and tighten them to the specified torque. Then tighten bolt A to the specified torque.

      Torque: 21 N*m (214 kgf*cm, 15 ft.*lbf) 

      Fig 7: Locating Transmission Oil Cooler Assembly Bolts With O-Rings
      G05629234Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  6. INSTALL AUTOMATIC TRANSMISSION ASSEMBLY 
    NOTE: Check that the 2 straight pins are attached to the engine side.
    1. Install the transmission with the 10 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) 

      Fig 8: Identifying Transmission Assembly Bolts Tightening Sequence
      G05629235Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  7. CONNECT TRANSMISSION OIL COOLER HOSE 
    1. Connect the 2 transmission oil cooler hoses to the transmission oil thermostat.
      NOTE:
      • Make sure the pinching portion of each clip is facing the direction shown in the illustration (Fig 9).
      • Make sure the paint mark of each hose is facing outward.
        Fig 9: Connecting Transmission Oil Cooler Hoses To Transmission Oil Thermostat
        G05629236Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  8. CONNECT NO. 2 WATER BY-PASS PIPE 
    1. Connect the 2 water by-pass hoses with the 2 clips and install the water by-pass pipe with the bolt.

      Torque: 18 N*m (184 kgf*cm, 13 ft.*lbf) 

      NOTE:
      • Make sure the pinching portion of each clip is facing the direction shown in the illustration (Fig 10).
      • Make sure the paint mark of each hose is facing outward.
    Fig 10: Connecting Water By-Pass Hoses With Clips
    G05629237Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  9. CONNECT WIRE HARNESS AND CONNECTOR 
    Fig 11: Connecting Wire Harness And Connector
    G05629238Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Connect the park/neutral position switch connector, 2 transmission wire connectors, 2 speed sensor connectors and 3 transfer control side connectors.

      HINT:

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

    2. Connect the 4 connector clamps and 6 harness clamps.
    3. Connect the wire harness with the bolt.

      Torque: 8.0 N*m (82 kgf*cm, 71 in.*lbf) 

    4. Tilt up the automatic transmission.
    5. Connect the ground cable with the bolt.

      Torque: 8.4 N*m (86 kgf*cm, 74 in.*lbf) 

      Fig 12: Locating Ground Cable Bolt
      G05629239Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  10. INSTALL REAR NO. 1 ENGINE MOUNTING INSULATOR 
    1. Install the rear engine mounting insulator to the transmission with the 4 bolts.

      Torque: 59 N*m (602 kgf*cm, 44 ft.*lbf) 

    2. Install the engine mounting heat insulator with the 2 bolts.

      Torque: 12 N*m (122 kgf*cm, 9 ft.*lbf) 

      Fig 13: Locating Rear Engine Mounting Insulator Bolts
      G05629240Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  11. INSTALL NO. 2 FRAME CROSSMEMBER SUBASSEMBLY 
    1. Install the frame crossmember to the rear engine mounting insulator with the 4 bolts.

      Torque: 37 N*m (377 kgf*cm, 27 ft.*lbf) 

      Fig 14: Locating Rear Engine Mounting Insulator Bolts
      G05629241Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the frame crossmember to the frame with the 4 bolts and 4 nuts.

      Torque: 110 N*m (1122 kgf*cm, 81 ft.*lbf) 

      Fig 15: Locating Frame Crossmember Nuts And Bolts
      G05629242Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Install the engine mounting hole cover.
      Fig 16: Identifying Engine Mounting Hole Cover
      G05629243Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  12. INSTALL DRIVE PLATE AND TORQUE CONVERTER CLUTCH SETTING BOLT 
    1. Turn the crankshaft to gain access to the installation locations of the 6 bolts and install the bolts while holding the crankshaft pulley set bolt with a wrench.

      Torque: 53 N*m (535 kgf*cm, 39 ft.*lbf) 

      NOTE: First install the black colored bolt and then the remaining 5 bolts.
      Fig 17: Locating Crankshaft Pulley Bolt
      G05629244Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the flywheel housing side cover.
  13. INSTALL STARTER ASSEMBLY  (See INSTALLATION )
  14. INSTALL STARTER COVER  (See INSTALLATION )
  15. INSTALL EXHAUST MANIFOLD SUB-ASSEMBLY RH  (See INSTALLATION )
  16. INSTALL NO. 1 EXHAUST MANIFOLD HEAT INSULATOR  (See INSTALLATION )
  17. INSTALL ENGINE OIL LEVEL DIPSTICK GUIDE  (See INSTALLATION )
    Fig 18: Installing Flywheel Housing Side Cover
    G05629245Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  18. INSTALL NO. 2 MANIFOLD STAY  (See INSTALLATION )
  19. INSTALL NO. 1 MANIFOLD STAY  (See INSTALLATION )
  20. INSTALL FRONT EXHAUST PIPE ASSEMBLY  (See INSTALLATION )
  21. INSTALL FRONT NO. 2 EXHAUST PIPE ASSEMBLY  (See INSTALLATION )
  22. INSTALL CENTER EXHAUST PIPE ASSEMBLY  (See INSTALLATION )
  23. INSTALL TAILPIPE ASSEMBLY  (See INSTALLATION )
  24. INSTALL PROPELLER SHAFT ASSEMBLY 
    1. Install the propeller shaft (See INSTALLATION ).
  25. INSTALL FRONT PROPELLER SHAFT ASSEMBLY 
    1. Install the front propeller shaft (See INSTALLATION ).
  26. CONNECT FLOOR SHIFT GEAR SHIFTING ROD SUB-ASSEMBLY 
    1. Connect the gear shifting rod to the transmission control shaft lever RH with the pin and a new clip.
  27. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL 
  28. ADD AUTOMATIC TRANSMISSION FLUID 
    1. Add automatic transmission fluid (See AUTOMATIC TRANSMISSION FLUID  ).
      Fig 19: Locating Pin
      G05629246Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  29. ADD ENGINE COOLANT  (See REPLACEMENT )
  30. INSPECT FOR ENGINE COOLANT LEAK  (See ON-VEHICLE INSPECTION )
  31. INSPECT SHIFT LEVER POSITION 
    1. When moving the shift lever from P to R with the engine switch on (IG) 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 rearward after moving the shift lever to R.

      If there are problems during the above inspections, perform the adjustment using the following procedures.

      1. Move the shift lever to N
      2. Loosen the nut of the floor shift gear shifting rod. Then, with the lever of the floor shift assembly lightly pushed towards the rear of the vehicle, tighten the nut.

        Torque: 13 N*m (133 kgf*cm, 10 ft.*lbf) 

  32. INSPECT FOR EXHAUST GAS LEAK  (See INSTALLATION )
  33. INSTALL UPPER RADIATOR SUPPORT SEAL 
    Fig 20: Pushing Lever
    G05629247Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  34. INSTALL OIL PAN PROTECTOR ASSEMBLY 
    1. Install the oil pan protector with the 4 bolts.

      Torque: 63 N*m (642 kgf*cm, 46 ft.*lbf) 

      Fig 21: Locating Oil Pan Protector Bolts
      G05629248Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  35. INSTALL NO. 1 ENGINE UNDER COVER 
    1. Install the under cover with the 6 bolts.

      Torque: 29 N*m (296 kgf*cm, 21 ft.*lbf) 

      Fig 22: Locating No. 1 Engine Under Cover Bolts
      G05629249Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  36. INSTALL NO. 2 ENGINE UNDER COVER 
    1. Install the under cover with the 6 bolts.

      Torque: 29 N*m (296 kgf*cm, 21 ft.*lbf) 

  37. INSTALL REAR FENDER SPLASH SHIELD SUBASSEMBLY LH  (See INSTALLATION )
  38. INSTALL REAR FENDER SPLASH SHIELD SUBASSEMBLY RH  (See INSTALLATION )
  39. RESET MEMORY 
    1. Perform the Reset Memory procedures (ATT initialization) (See INITIALIZATION  ).
      Fig 23: Locating No. 2 Engine Under Cover Bolts
      G05629250Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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