Automatic Transaxle Assembly: Removal

NOTE:

When the automatic transaxle is replaced, the transaxle's compensation code must be input into the TCM(See REGISTRATION ).
When the TCM is replaced, the existing transaxle compensation codes must be input into the new TCM (See REGISTRATION ).
If the following parts have been replaced, initialize the TCM and perform a road test to allow the TCM to learn (See INITIALIZATION ).
- Valve body assembly
- Shift solenoid SL3
- Shift solenoid SL4
If the following parts have been replaced, perform a road test to allow the TCM to learn (See INITIALIZATION ).
- Shift solenoid SL1
- Shift solenoid SL2
If the TCM or transaxle has been replaced, register the transmission compensation code in the TCM (See REGISTRATION ).
Perform RESET MEMORY (AT initialization) when replacing the automatic transmission assembly, engine assembly or ECM (See INITIALIZATION ).

DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL
REMOVE V-BANK COVER SUB-ASSEMBLY
1. Hold the front of the V-bank cover and raise it to disengage the 2 clips on the front of the cover. Continue to raise the cover to disengage the clip on the rear of the cover and remove the cover.
  NOTE: Attempting to disengage both front and rear clips at the same time may cause the cover to break.
  
  Fig 1: Identifying V-Bank Cover
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE COOL AIR INTAKE DUCT SEAL
1. Remove the 7 clips and intake duct seal.
  
  Fig 2: Identifying Hood Hinge Cover LH And Clips
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE ENGINE ROOM SIDE COVER LH
1. Remove the hood hinge cover LH.
2. Remove the 6 clips and engine room side cover LH.
  
  Fig 3: Identifying Hood Hinge Cover LH And Clips
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE ENGINE ROOM SIDE COVER RH
1. Remove the hood hinge cover RH.
2. Remove the 5 clips and engine room side cover RH.
  
  Fig 4: Identifying Engine Room Side Cover And Clips
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE BATTERY
1. Loosen the nut, and remove the bolt and battery clamp.
  
  Fig 5: Identifying Battery Clamp And Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Remove the battery and battery tray.
REMOVE NO. 2 AIR CLEANER INLET
1. Remove the 2 bolts, clamp and No. 2 air cleaner inlet.
  
  Fig 6: Identifying Bolts, Clamp And Air Cleaner Inlet
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE AIR CLEANER CAP SUB-ASSEMBLY
1. Disconnect the 2 vacuum hoses.
  
  Fig 7: Identifying Vacuum Hoses
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Disconnect the mass air flow meter connector (^* 1).
  
  Fig 8: Locating Mass Air Flow Meter Connector, Ventilation Hose And Hose Band
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Disconnect the No. 2 ventilation hose (^* 2).
4. Disconnect the hose band (^* 3).
5. Disconnect the 3 bands, and remove the air cleaner cap sub-assembly.
  
  Fig 9: Locating Air Cleaner Cap Sub-Assembly Bands
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE AIR CLEANER CASE SUB-ASSEMBLY
1. Disconnect the vacuum hose and hose clamp.
  
  Fig 10: Identifying Vacuum Hose, Hose Clamp And Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Remove the 3 bolts and air cleaner case.
REMOVE NO. 1 AIR CLEANER INLET
1. Remove the bolt and No. 1 air cleaner inlet.
  
  Fig 11: Identifying No. 1 Air Cleaner Inlet And Bolt
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE STARTER ASSEMBLY
1. Disconnect the terminal 50 connector from the starter assembly.
  
  Fig 12: Locating Starter Assembly Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Remove the nut and disconnect the wire harness from terminal 30.
3. Remove the 2 bolts and starter assembly.
REMOVE TRANSAXLE BREATHER HOSE
1. Remove the bolt and breather bracket from the camshaft housing sub-assembly LH.
  
  Fig 13: Locating Breather Bracket Bolt
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Remove the breather hose from the breather bracket.
Install the 2 bolts and 2 clamps to the body.

Fig 14: Locating Body Bolts And Clamps
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
DISCONNECT PNP CONNECTOR
1. Disconnect the park/neutral position switch connector.
  
  Fig 15: Locating Park/Neutral Position Switch Connector
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Remove the upper bell housing (5) bolts.

Fig 16: Locating Upper Bell Housing Bolts
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
DISCONNECT TRANSMISSION CONTROL CABLE ASSEMBLY
1. Remove the nut from the control shaft lever.
  
  Fig 17: Locating Transmission Control Cable Nut
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Disconnect the transmission control cable assembly from the control shaft lever.
3. Remove the clip and disconnect the transmission control cable assembly from the No. 1 transmission control cable bracket.
  
  Fig 18: Locating Transmission Cable Bracket Clip
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL ENGINE HANGER
1. Install the 2 engine hangers with the 4 bolts as shown in the illustration.
  
  Fig 19: Identifying Engine Hangers And Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Part No
  
  No. 1 engine hanger 12281-31120
  
  No. 2 engine hanger 12282-31100
  
  Bolts 91671-10825
  
  Torque: 33 N*m (337 kgf*cm, 24 ft.*lbf)
INSTALL THE ENGINE SUPPORT BAR AND SECURE ENGINE WEIGHT WITH CHAIN
SST: 00002-ESUPPT-01

NOTE: Refer to the assembly instructions supplied with the Engine Support Bar.
1. Assemble and place the main bar onto the vehicle's strut towers.
  NOTE:
  - To prevent damage caused by contact between the main bar legs and body panels, apply protective tape on the strut tower before installing the main bar.
  - To prevent dents in the strut tower panel, please assure that the main bar legs with 90 degree brackets are installed.
  NOTE:
  - Ensure that the main bar swivel is already installed on the main bar and that the main bar legs are oriented correctly (passenger side/drivers side).
  - The plastic cowl cover and/or cowl may need to be removed to accommodate the bar.
  Fig 21: Main Bar Mounted To Strut Tower
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Assemble the front bar assembly and position the legs so they can sit onto the right and left frame rails.
  
  Fig 22: Front Bar Positioned On Frame Rails
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Adjust the front bar arms so they can be bolted to the upper radiator core support mounting holes.
  
  Fig 23: Main Bar Mounted To Strut Tower
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Place the front bar on the vehicle with the legs sitting firmly on the right and left frame rails near the radiator support, and secure the front bar arms to the radiator core support.
  
  Fig 24: Main Bar Mounted To Strut Tower
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  NOTE: Once in position, ensure that the hex nuts on the front bar legs are tight and the front bar is still square after installation.
5. Install the Engine Support Bar hook #2 onto the crossbar and place the crossbar assembly through the swivel on the main bar.
  NOTE: The main bar swivel may be placed above or below the main bar.
  
  NOTE: Be sure not to let the main bar swivel fall and damage the windshield, or damage the hood when installing the crossbar assembly.
  
  Fig 25: Main Bar Mounted To Strut Tower
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
6. Insert the straddle bar into the crossbar.
  
  Fig 26: Main Bar Mounted To Strut Tower
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
7. Adjust the height of the crossbar so it is level and insert the quick release pin through the nearest open slot in the straddle bar.
8. Attach the chain from the engine hooks to the hook #2 of the Engine Support Bar and place tension on the chain until the Engine Support Bar self centers.
  CAUTION: Ensure the Engine Support Bar is stable when fully assembled and mounted to the vehicle to ensure no damage to vehicle or technician.
PLACE FRONT WHEELS FACING STRAIGHT AHEAD
REMOVE FRONT WHEELS
REMOVE ENGINE UNDER COVER LH
REMOVE ENGINE UNDER COVER RH
REMOVE FRONT FENDER APRON SEAL RH
REMOVE FRONT FENDER APRON SEAL LH
DRAIN AUTOMATIC TRANSAXLE FLUID
1. Remove the refill plug and gasket.
  
  Fig 28: Locating Refill Plug
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using a 6 mm socket hexagon wrench, remove the overflow plug and gasket.
  
  Fig 29: Locating Overflow Plug
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Using a 6 mm socket hexagon wrench, remove the No. 1 transmission oil filler tube.
4. Drain the automatic transaxle fluid.
  
  Fig 30: Identifying Transmission Oil Filler Tube
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
5. Using a 6 mm socket hexagon wrench, install the No. 1 transmission oil filler tube.
  Torque: 1.7 N*m (17 kgf*cm, 15 in.*lbf)
  
  Fig 31: Identifying Transmission Oil Filler Tube
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
6. Using a 6 mm socket hexagon wrench, install the overflow plug with a new gasket.
  Torque: 40 N*m (408 kgf*cm, 30 ft.*lbf)
  
  Fig 32: Locating Overflow Plug
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
7. Install the refill plug with a new gasket.
  Torque: 49 N*m (500 kgf*cm, 36 ft.*lbf)
  
  Fig 33: Locating Refill Plug
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE FRONT AXLE HUB NUTS
1. Using SST and a hammer, release the staked part of the front axle hub nut.
  SST 09930-00010
  
  NOTE: Loosen the staked part of the nut completely, otherwise the thread of the drive shaft may be damaged.
2. While applying the brakes, remove the front axle hub nut.
  
  Fig 34: Tapping Front Axle Hub Lock Nut
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
SEPARATE FRONT SUSPENSION LOWER NO. 1 ARM
1. Remove the bolt and 2 nuts, and separate the front suspension lower No. 1 arm from the lower ball joint.
  
  Fig 35: Locating Front Suspension Arm Sub-Assembly Lower No. 1 LH Nuts And Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE FRONT DRIVE SHAFT ASSEMBLY LH
1. Using SST, remove the front drive shaft assembly LH.
  SST 09520-01010, 09520-24010 (09520-32040)
  NOTE:
  - Be careful not to damage the drive shaft dust cover, boot, or oil seal.
  - Be careful not to drop the drive shaft assembly.
    
    Fig 36: Removing Front Drive Shaft Assembly LH
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE FRONT DRIVE SHAFT ASSEMBLY RH
1. Using a screwdriver, remove the bearing bracket hole snap ring.
2. Remove the bolt and front drive shaft assembly RH from the drive shaft bearing bracket.
  NOTE: Do not damage the boot or oil seal.
  
  Fig 37: Locating Front Drive Shaft Assembly RH Bolt
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Separate the front stabilizer link assembly by removing the nut.

Fig 38: Identifying Front Stabilizer Link Nut
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Disconnect the oil cooler hoses.
1. Release the clamp and disconnect the oil cooler inlet hose.
2. Release the clamp and disconnect the oil cooler outlet hose.
Fig 39: Locating Oil Cooler Hoses
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Disconnect the two O2 sensor connectors from the wiring harness and unhook from the sub-frame wiring bracket.
REMOVE EXHAUST PIPE ASSEMBLY FRONT
1. Remove the 2 nuts from the exhaust pipe front (left bank exhaust manifold side).
2. Remove the 2 bolts from the exhaust pipe front (right bank exhaust pipe manifold side). Then remove the exhaust pipe front.
3. Remove the 3 gaskets from the exhaust pipe front. (exhaust pipe center side). Then remove the exhaust pipe front.
4. Remove the 3 gaskets from the exhaust pipe front.
  
  Fig 40: Locating Exhaust Pipe Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE DRIVE PLATE AND TORQUE CONVERTER CLUTCH SETTING BOLT
1. Remove the 2 bolts and flywheel housing under cover.
  
  Fig 41: Locating Flywheel Housing Under Cover Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Turn the crankshaft to gain access and remove the 6 bolts while holding the crankshaft pulley bolt with a wrench.
  
  Fig 42: Locating Torque Converter Clutch Mounting Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Remove the engine mounting insulators bolts and nuts from sub-frame assembly. Remove the 5 hole plugs.

Fig 43: Locating Engine Mounting Hole Plugs
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Remove the 9 nuts, and separate the front frame assembly.

Fig 44: Locating Front Frame Assembly Bolts
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Remove the bolts that hold down the power steering line to the sub frame.
Remove the bolts that hold the power steering link assembly to the sub frame. Remove the 2 bolts, 2 nuts, and the power steering link assembly.
NOTE: Because the nut has its own stopper, do NOT turn the nut. Loosen the bolt with the nut fixed.

Fig 45: Locating Steering Assembly Bolts
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Install the SST 00002-2SUPP, secondary safety support straps.
SST: 00002-2SUPP
1. Loop the strap over the frame rail rearward of the radiator support and secure the hook to the strap's floating D-ring.
2. Feed the strap over the sub-frame and under the engine in an "X" pattern.
3. Connect the strap's hook into the torque box tie-down holes. This allows the sub frame to be removed without the need to remove the support strap.
4. Ratchet the support strap until it is snugly seated on the engine and transaxle assembly.

NOTE: Make sure that the engine moving control rod is NOT disconnected because the rod is also used as additional safety support.

Place a lift under the sub frame.
Remove the remaining (12) bolts holding the sub frame to the vehicle.

Fig 49: Locating Bolts, Nuts, Front Suspension Member Brace Rear RH And LH

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

CAUTION: Before removing the bolts ensure the Engine Support Bar is secure and is supporting the engine weight to ensure no damage to vehicle or technician.

Slowly lower the sub frame.
Place a transmission jack under the transmission.
Remove the lower (6) bell housing bolts.

Fig 50: Locating Lower Bell Housing Bolts

Lower the transmission away from the vehicle.