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Automatic Transaxle Assembly: Installation

  1. INSTALL TORQUE CONVERTER CLUTCH ASSEMBLY 
    1. Install the torque converter clutch to the automatic transaxle.
    2. Using vernier calipers and a straight edge, measure dimension "A" between the transaxle fitting part of the engine and the converter fitting part of the drive plate (#).
      Fig 1: Measuring Dimension "A" Between Transaxle Fitting Part
      G05271942Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Aligning the matchmarks on the transmission case and torque converter clutch assembly, engage the splines of the input shaft and turbine runner.
      NOTE: Do not push on the torque converter when aligning the matchmarks.
      Fig 2: Engaging Splines Of Input Shaft And Turbine Runner
      G05271943Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Engage the splines of the stator shaft and the stator while turning the torque converter clutch assembly.

      HINT:

      Turn the torque converter clutch assembly approximately 180°.

      Fig 3: Engaging Splines Of Stator Shaft And Stator
      G05271944Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Turn the torque converter clutch assembly and align the matchmarks on the torque converter clutch assembly and transmission case to engage the key of the oil pump drive gear into the slot on the torque converter clutch assembly.
      Fig 4: Engaging Key Of Oil Pump Drive Gear Into Slot On Torque Converter Clutch Assembly
      G05271945Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    6. Using vernier calipers and a straight edge, measure dimension "B" shown in the illustration and check that "B" is greater than "A" (measured in step (#)).

      Standard: A + 1 mm (0.04 in.) or more 

      NOTE: Make sure to deduct the thickness of the straight edge.
      Fig 5: Measuring Dimension B
      G05271946Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  2. INSTALL AUTOMATIC TRANSMISSION WITH TRANSFER 
    1. Install the automatic transaxle with transfer to the engine with the 10 bolts.

      Torque: Bolt A 

      64 N*m (650 kgf*cm, 47 ft.*lbf) 

      Bolt B 

      46 N*m (470 kgf*cm, 34 ft.*lbf) 

      Bolt C 

      43 N*m (438 kgf*cm, 32 ft.*lbf) 

      Fig 6: Locating Automatic Transaxle Bolts
      G05271947Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Apply a few drops of adhesive to each of 2 threads on the tip of the 6 torque converter clutch mounting bolts.

      Adhesive: Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent 

    3. Install the 6 torque converter clutch mounting bolts.

      Torque: 41 N*m (418 kgf*cm, 30 ft.*lbf) 

      NOTE: First install the green colored bolt, and then the remaining 5 bolts.
      Fig 7: Locating Crankshaft Pulley Bolt
      G05271948Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Install the flywheel housing under cover to the automatic transaxle with the 2 bolts.

      Torque: 7.8 N*m (80 kgf*cm, 69 in.*lbf) 

      Fig 8: Identifying Bolt And Flywheel Housing Under Cover
      G05271949Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  3. INSTALL ENGINE MOUNTING BRACKET FRONT 
    1. Install the engine mounting bracket front to the automatic transaxle with the 3 bolts.

      Torque: 64 N*m (650 kgf*cm, 47 ft.*lbf) 

  4. INSTALL TRANSMISSION OIL FILLER TUBE SUB-ASSEMBLY 
    1. Coat a new O-ring with ATF, and install it to the transmission oil filler tube sub-assembly.
      Fig 9: Locating Engine Mounting Bracket And Bolts
      G05271950Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the transmission oil filler tube sub-assembly to the automatic transaxle with the bolt.

      Torque: 5.5 N*m (56 kgf*cm, 49 in.*lbf) 

  5. INSTALL NO. 1 OIL COOLER INLET TUBE 
    1. Temporarily install the No. 1 oil cooler outlet tube.
    2. Temporarily install the No. 1 oil cooler inlet tube.
      Fig 10: Locating Transmission Oil Filter Tube Bolt
      G05271951Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Install the oil cooler tube clamp with the bolt.

      Torque: 5.4 N*m (55 kgf*cm, 48 in.*lbf) 

      HINT:

      Install them so that the oil cooler tube cushion is positioned as shown in the illustration.

      Fig 11: Locating Oil Cooler Tube Clamp Bolt
      G05271952Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Install the No. 1 oil cooler inlet tube.

      Torque: 34 N*m (347 kgf*cm, 25 ft.*lbf) 

      Fig 12: Installing No. 1 Oil Cooler Inlet Tube
      G05271953Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  6. INSTALL NO. 1 OIL COOLER OUTLET TUBE 
    1. Install the No. 1 oil cooler outlet tube.

      Torque: 34 N*m (347 kgf*cm, 25 ft.*lbf) 

      Fig 13: Installing No. 1 Oil Cooler Outlet Tube
      G05271954Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  7. INSTALL NO. 1 TRANSMISSION CONTROL CABLE BRACKET 
    1. Install the control cable bracket No.1 with the 2 bolts.

      Torque: 12 N*m (122 kgf*cm, 10 ft.*lbf) 

      Fig 14: Locating No. 1 Transmission Control Cable Bracket Bolts
      G05271955Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  8. CONNECT BREATHER PLUG HOSE 
    1. Connect the breather hose to the oil filler tube.
      Fig 15: Identifying Breather Plug Hose
      G05271956Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  9. CONNECT CONNECTORS 
    1. Connect the transmission wire connector.
    2. Connect the park/neutral position switch connector.
    3. Connect the 2 transmission revolution sensor connectors.
  10. INSTALL STARTER ASSEMBLY  (See INSTALLATION )
    Fig 16: Identifying Transmission Revolution Sensor Connectors
    G05271957Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  11. CONNECT WIRE HARNESS 
    1. Connect the wire harness with the bolt.

      Torque: 19 N*m (193 kgf*cm, 14 ft.*lbf) 

      Fig 17: Locating Wire Harness Bolt
      G05271958Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  12. INSTALL WIRE HARNESS CLAMP 
    1. Install the 4 clamps and 4 bolts.

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

    2. Connect the wire harnesses to the clamps.
      Fig 18: Locating Wire Harnesses Clamps Bolts
      G05271959Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  13. INSTALL NO. 2 TRANSMISSION CONTROL CABLE BRACKET 
    1. Install the transmission control cable bracket No. 2 with the bolt.

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

  14. INSTALL MANIFOLD STAY  (See INSTALLATION )
  15. INSTALL ENGINE WIRE 
  16. INSTALL FRONT DRIVE SHAFT ASSEMBLY LH  (See INSTALLATION )
    Fig 19: Locating No. 2 Transmission Control Cable Bracket And Bolt
    G05271960Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  17. INSTALL FRONT DRIVE SHAFT ASSEMBLY RH  (See INSTALLATION )
  18. INSTALL FRONT FRAME ASSEMBLY  (See INSTALLATION )
  19. INSTALL VANE PUMP ASSEMBLY  (See INSTALLATION )
  20. INSTALL ENGINE ASSEMBLY WITH TRANSAXLE  (See INSTALLATION )
  21. INSTALL COOLER COMPRESSOR ASSEMBLY  (See INSTALLATION )
  22. INSTALL GENERATOR ASSEMBLY  (See INSTALLATION )
  23. INSTALL HEIGHT CONTROL SENSOR SUB-ASSEMBLY FRONT LH (w/ Air Suspension)  (See INSTALLATION )
  24. INSTALL HEIGHT CONTROL SENSOR SUB-ASSEMBLY FRONT RH (w/ Air Suspension)  (See INSTALLATION )
  25. INSTALL STEERING INTERMEDIATE SHAFT SUB-ASSEMBLY  (See INSTALLATION )
  26. INSTALL NO. 1 EXHAUST PIPE SUPPORT BRACKET  (See INSTALLATION )
  27. INSTALL FRONT AXLE ASSEMBLY LH  (See INSTALLATION )
  28. INSTALL FRONT AXLE ASSEMBLY RH  (See INSTALLATION )
  29. CONNECT FRONT SUSPENSION LOWER NO. 1 ARM LH  (See INSTALLATION )
  30. CONNECT FRONT SUSPENSION LOWER NO. 1 ARM RH  (See INSTALLATION )
  31. INSTALL TIE ROD ASSEMBLY LH  (See INSTALLATION )
  32. INSTALL TIE ROD ASSEMBLY RH  (See INSTALLATION )
  33. INSTALL FRONT SPEED SENSOR LH  (See INSTALLATION )
  34. INSTALL FRONT SPEED SENSOR RH  (See INSTALLATION )
  35. INSTALL FRONT STABILIZER LINK ASSEMBLY LH  (See INSTALLATION )
  36. INSTALL FRONT STABILIZER LINK ASSEMBLY RH  (See INSTALLATION )
  37. INSTALL FRONT AXLE HUB NUT LH  (See INSTALLATION )
  38. INSTALL FRONT AXLE HUB NUT RH  (See INSTALLATION )
  39. INSTALL EXHAUST PIPE ASSEMBLY FRONT  (See INSTALLATION )
  40. INSTALL NO. 3 EXHAUST PIPE SUB-ASSEMBLY FRONT  (See INSTALLATION )
  41. INSTALL OXYGEN SENSOR  (See INSTALLATION )
  42. CONNECT NO. 1 OIL RESERVOIR TO PUMP HOSE  (See INSTALLATION )
  43. CONNECT RETURN TUBE SUB-ASSEMBLY  (See INSTALLATION )
  44. CONNECT FUEL TUBE SUB-ASSEMBLY  (See INSTALLATION )
  45. CONNECT TRANSMISSION CONTROL CABLE ASSEMBLY  (See INSTALLATION )
  46. CONNECT ENGINE WIRE  (See INSTALLATION )
  47. INSTALL GLOVE COMPARTMENT DOOR ASSEMBLY  (See INSTALLATION )
  48. INSTALL JUNCTION BLOCK COVER 
  49. CONNECT HEATER INLET WATER HOSE  (See INSTALLATION )
  50. CONNECT HEATER OUTLET WATER HOSE  (See INSTALLATION )
  51. CONNECT OIL COOLER INLET HOSE  (See INSTALLATION )
  52. CONNECT OIL COOLER OUTLET HOSE  (See INSTALLATION )
  53. INSTALL RADIATOR HOSE INLET  (See INSTALLATION )
  54. INSTALL RADIATOR HOSE OUTLET  (See INSTALLATION )
  55. CONNECT UNION TO CHECK VALVE HOSE  (See INSTALLATION )
  56. CONNECT NO. 1 FUEL VAPOR FEED HOSE  (See INSTALLATION )
  57. INSTALL ENGINE MOVING CONTROL ROD SUB-ASSEMBLY  (See INSTALLATION )
  58. INSTALL NO. 2 ENGINE MOUNTING STAY RH  (See INSTALLATION )
  59. INSTALL AIR CLEANER BRACKET  (See INSTALLATION )
  60. INSTALL INTAKE AIR RESONATOR SUB-ASSEMBLY  (See INSTALLATION )
  61. INSTALL BATTERY  (See INSTALLATION )
  62. INSTALL NO. 1 AIR CLEANER INLET  (See INSTALLATION )
  63. INSTALL AIR CLEANER CASE SUB-ASSEMBLY  (See INSTALLATION )
  64. INSTALL AIR CLEANER CAP SUB-ASSEMBLY  (See INSTALLATION )
  65. INSTALL NO. 2 AIR CLEANER INLET  (See INSTALLATION )
  66. CONNECT VACUUM HOSES  (See INSTALLATION )
  67. INSTALL V-RIBBED BELT  (See INSTALLATION )
  68. INSTALL COWL TOP PANEL OUTER PANEL SUB-ASSEMBLY  (See INSTALLATION )
  69. INSTALL WINDSHIELD WIPER LINK ASSEMBLY  (See INSTALLATION )
  70. INSTALL FRONT WHEELS  (See INSTALLATION )
  71. ADD ENGINE OIL 
  72. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL  (See INSTALLATION )
  73. ADD ENGINE COOLANT  (See ON-VEHICLE INSPECTION )
  74. ADD AUTOMATIC TRANSAXLE FLUID 
  75. ADD POWER STEERING FLUID 
  76. BLEED POWER STEERING FLUID  (See BLEEDING )
  77. CHECK FOR FUEL LEAKS  (See ON-VEHICLE INSPECTION )
  78. CHECK FOR ENGINE OIL LEAKS 
  79. CHECK FOR ENGINE COOLANT LEAKS  (See ON-VEHICLE INSPECTION )
  80. CHECK FOR EXHAUST GAS LEAKS 
  81. CHECK SHIFT LEVER POSITION  (See INSTALLATION  )
  82. CHECK AND ADJUST FRONT WHEEL ALIGNMENT  (See INSTALLATION )
  83. CHECK IGNITION TIMING  (See ON-VEHICLE INSPECTION )
  84. CHECK ENGINE IDLE SPEED  (See ON-VEHICLE INSPECTION )
  85. CHECK CO/HC  (See ON-VEHICLE INSPECTION )
  86. CHECK FUNCTION OF THROTTLE BODY  (See ON-VEHICLE INSPECTION )
  87. INSTALL FRONT FENDER APRON SEAL RH 
  88. INSTALL FRONT FENDER SPLASH SHIELD SUB-ASSEMBLY RH 
  89. INSTALL NO. 2 ENGINE UNDER COVER (w/ No. 2 engine under cover) 
  90. INSTALL NO. 1 ENGINE UNDER COVER 
  91. INSTALL ENGINE UNDER COVER ASSEMBLY (w/ engine under cover assembly) 
  92. INSTALL V-BANK COVER SUB-ASSEMBLY  (See INSTALLATION )
  93. INSTALL ENGINE ROOM COVER SIDE (for LHD)  (See INSTALLATION )
  94. INSTALL COOL AIR INTAKE DUCT SEAL  (See INSTALLATION )
  95. CHECK ABS SPEED SENSOR SIGNAL  (See INSTALLATION )
  96. PREFORM INITIALIZATION 

    HINT:

    Some systems need initialization after reconnecting the cable to the negative battery terminal (See INITIALIZATION ).

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