Automatic Transmission Assembly: Installation: Installation

INSTALL TORQUE CONVERTER CLUTCH ASSEMBLY

Fig 1: Measuring Torque Converter Clutch Assembly With Caliper & Straightedge
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
1. 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. Align the matchmarks on the transmission case and torque converter clutch, and then mesh the splines of the input shaft and turbine runner.
  
  Fig 2: Identifying Alignment Matchmarks On Transmission Case & Torque Converter Clutch
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  TEXT IN ILLUSTRATION
  
  *1 Matchmark
3. Mesh the splines of the stator shaft and stator while turning the torque converter clutch.
  HINT:
  
  Turn the torque converter clutch approximately 180°.
  
  Fig 3: Identifying Torque Converter Clutch Orientation
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  TEXT IN ILLUSTRATION
  
  *1 Matchmark
4. 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.
  TEXT IN ILLUSTRATION
  
  *1 Matchmark
  
  NOTE:
  Do not push on the torque converter when aligning the matchmarks.
  
  Fig 4: Identifying Alignment Matchmarks On Transmission Case & Torque Converter Clutch
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
5. Using a vernier caliper and straightedge, measure dimension B shown in the illustration and check that B is more than A (measured in step 1).
  Standard distance
  
  A + 1 mm (0.0394 in.) or more
  
  Fig 5: Measuring Torque Converter Clutch Assembly With Caliper & Straightedge
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL TRANSFER ASSEMBLY
1. Install the transfer. Refer to INSTALLATION .
INSTALL TRANSMISSION CONTROL CABLE BRACKET
1. Install the bracket with the 2 bolts.
  Torque: 14 N*m)143 kgf*cm, 10 ft.*lbf)
INSTALL WIRE HARNESS CLAMP BRACKET

Fig 6: Identifying Wire Harness Clamp Brackets & Bolts
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
1. Install the 7 wire harness clamp brackets with the 7 bolts.
  Torque: 8.0 N*m)82 kgf*cm, 71 in.*lbf)

INSTALL AUTOMATIC TRANSMISSION ASSEMBLY

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

Fig 7: Identifying Knock Pins & Crankshaft

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

TEXT IN ILLUSTRATION

*1	Knock Pin
*2	Crankshaft
*a	Surface of crankshaft that contacts torque converter clutch centerpiece

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.)
Install the transmission with the 10 bolts.

Fig 8: Identifying Torque Converter Clutch Centerpiece Head Bolts
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

for 17 mm head bolt A

Torque: 71 N*m)724 kgf*cm, 52 ft.*lbf)

for 14 mm head bolt B

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

INSTALL TRANSMISSION OIL COOLER ASSEMBLY
1. Connect the 2 hoses to the oil cooler tube unions.
  
  Fig 9: Identifying Transmission Oil Cooler Tube Unions, Hoses & Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Temporarily install the transmission oil cooler together with the transmission oil thermostat with bolt A. Install bolts B and C 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)
3. Connect the No. 2 oil cooler inlet hose and No. 2 oil cooler outlet hose to the transmission oil thermostat.
  
  Fig 10: Identifying Orientation Of No. 2 Oil Cooler Hose Clips (Inlet & Outlet)
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  NOTE:
  Make sure the pinching portion of each clip is facing the direction shown in the illustration.

CONNECT NO. 1 WATER BY-PASS PIPE

Connect the water by-pass pipe to the transmission with the 2 bolts.

Fig 11: Identifying No. 1 Water By-Pass Pipe Bolts & Paint Marks
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

Connect the 2 water by-pass hoses to the transmission oil cooler.

TEXT IN ILLUSTRATION

*1	White Paint Mark
*2	Blue Paint Mark

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.

CONNECT WIRE HARNESS AND CONNECTOR
1. Connect the park/neutral position switch connector, transmission wire connector, 2 speed sensor connectors and transfer control connector.
  
  Fig 12: Identifying Wire Harness & Connectors
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  HINT:
  
  Push up the lever until the claw of the transmission wire connector makes a connection sound.
2. Attach the 2 connector clamps and 8 harness clamps.
3. Connect the crankshaft position sensor connector and connect the wire harness with the nut.
  Torque: 8.0 N*m)82 kgf*cm, 71 in.*lbf)
4. Install the No. 2 wire harness heat insulator with the 2 nuts.
  Torque: 8.0 N*m)82 kgf*cm, 71 in.*lbf)
5. Tilt up the automatic transmission.
6. Connect the ground cable with the nut.
  Torque: 5.5 N*m)56 kgf*cm, 49 in.*lbf)
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)
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)
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)
INSTALL DRIVE PLATE AND TORQUE CONVERTER CLUTCH SETTING BOLT

Fig 13: Identifying Crankshaft Pulley Setting And Bolt
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
1. 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: 53 N*m)535 kgf*cm, 39 ft.*lbf)
  
  NOTE:
  Install the black bolt first, and then the 5 silver bolts.
2. Install the flywheel housing side cover.
  
  Fig 14: Flywheel Housing Side Cover
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL STARTER ASSEMBLY
1. Install the starter. Refer to INSTALLATION .
CONNECT TRANSMISSION CONTROL CABLE ASSEMBLY
1. Connect the transmission control cable to the transmission control cable bracket with a new clip and connect the cable end to the control shaft lever with the nut.
  Torque: 14 N*m)143 kgf*cm, 10 ft.*lbf)
INSTALL FRONT EXHAUST PIPE ASSEMBLY
1. Install the front exhaust pipe. Refer to INSTALLATION .
INSTALL PROPELLER SHAFT ASSEMBLY
1. Install the propeller shaft. Refer to INSTALLATION .
INSTALL FRONT PROPELLER SHAFT ASSEMBLY
1. Install the front propeller shaft. Refer to INSTALLATION .
CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
NOTE:
When disconnecting the cable, some systems need to be initialized after the cable is reconnected. Refer to INITIALIZATION .
ADD AUTOMATIC TRANSMISSION FLUID
1. Add automatic transmission fluid. Refer to ADJUSTMENT .
ADD ENGINE COOLANT . Refer to REPLACEMENT - Step 6
INSPECT FOR ENGINE COOLANT LEAK . Refer to ON-VEHICLE INSPECTION - Step 1
ADJUST SHIFT LEVER POSITION See step 2
INSPECT SHIFT LEVER POSITION See step 1
INSPECT FOR EXHAUST GAS LEAK . Refer to INSTALLATION - Step 17
INSTALL PROPELLER SHAFT HEAT INSULATOR
1. Install the propeller shaft heat insulator with the 2 bolts.
  Torque: 16 N*m)160 kgf*cm, 12 ft.*lbf)
INSTALL REAR ENGINE UNDER COVER ASSEMBLY . Refer to INSTALLATION - Step 86
INSTALL NO. 1 ENGINE UNDER COVER SUB-ASSEMBLY . Refer to INSTALLATION - Step 88
RESET MEMORY
1. Perform the Reset Memory procedures (A/T initialization). Refer to INITIALIZATION .