Automatic Transaxle Assembly: Installation

1. INSPECT TORQUE CONVERTER CLUTCH ASSEMBLY  (See TORQUE CONVERTER CLUTCH AND DRIVE PLATE )
2. INSTALL TORQUE CONVERTER CLUTCH ASSEMBLY 
   1. Using a vernier caliper, measure dimension A between the transaxle contact surface of the engine and the converter contact surface of the drive plate.

      HINT:

      The ring gear end surface and the converter contact surface are same level.

      Fig 1: Measuring Dimension Between Transaxle Contact Surface Of Engine

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   2. Set the key at the top of the front oil pump drive gear and put a matchmark on the housing.
      Fig 2: Identifying Matchmark On Housing

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   3. Put a matchmark on the torque converter so that its groove is clearly indicated.
      Fig 3: Identifying Matchmark On Torque Converter

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   4. Align the matchmark on the case with the one on the converter and fit the spline of the input shaft to the spline of the turbine runner.
      Fig 4: Aligning Matchmark On Converter

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   5. Rotating the converter, fit the spline of the stator shaft with that of the stator.

      HINT:

      Rotate the converter approximately 180 degrees.

      Fig 5: Identifying Matchmark On Converter

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   6. Rotating the converter, align the mark on the case with the one on the converter again and fit the key of the oil pump drive gear into the key-way of the converter.
      NOTE: Do not apply excessive force to the converter when rotating it.
      Fig 6: Aligning Mark On Converter

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   7. Using vernier calipers and a straightedge, measure dimension B shown in the illustration and check that dimension B is greater than dimension A, which was measured in step (a).

      Standard: 

      A + 1 mm (0.0394 in.) or more 

      NOTE: Subtract the thickness of the straightedge from the measured value to obtain dimension B.
      Fig 7: Checking Converter Dimension

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. INSTALL SPEEDOMETER DRIVEN HOLE COVER SUB-ASSEMBLY 
   1. Install the speedometer driven hole cover sub-assembly to the automatic transaxle with the bolt.

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

      Fig 8: Locating Speedometer Driven Hole Cover Sub-Assembly Bolt

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. INSTALL NO. 1 TRANSMISSION CONTROL CABLE BRACKET 
   1. Install the No. 1 transmission control cable bracket to the automatic transaxle with the 2 bolts.

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

      Fig 9: Locating No. 1 Transmission Control Cable Bracket And Bolts

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
5. INSTALL REAR ENGINE MOUNTING BRACKET 
   1. Install the rear engine mounting bracket to the automatic transaxle with the 3 bolts.

      Torque: 45 N*m (459 kgf*cm, 33 ft.*lbf) 

      Fig 10: Locating Rear Engine Mounting Bracket Bolts

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
6. INSTALL FRONT ENGINE MOUNTING BRACKET 
   1. Install the front engine mounting bracket to the automatic transaxle with the 4 bolts.

      Torque: 64 N*m (653 kgf*cm, 47 ft.*lbf) 

      Fig 11: Locating Front Engine Mounting Bracket Bolts

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
7. INSTALL ENGINE MOUNTING BRACKET LH 
   1. Install the engine mounting bracket LH to the automatic transaxle with the 3 bolts.

      Torque: 52 N*m (530 kgf*cm, 38 ft.*lbf) 

      Fig 12: Locating Engine Mounting Bracket Bolts

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
8. INSTALL AUTOMATIC TRANSAXLE ASSEMBLY 
   NOTE: Confirm that 2 knock pins are on the transaxle contact surface of the engine block before the transaxle installation.
   1. Install the automatic transaxle to the engine with the 7 bolts.

      Torque: 30 N*m (301 kgf*cm, 22 ft.*lbf) 

      Fig 13: Locating Automatic Transaxle Bolts

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
9. INSTALL ENGINE MOUNTING INSULATOR LH 
   1. Install the engine mounting insulator LH with the through bolt and nut.

      Torque: 56 N*m (571 kgf*cm, 41 ft.*lbf) 

      Fig 14: Locating Engine Mounting Insulator Bolt

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
10. INSTALL STARTER ASSEMBLY  (See INSTALLATION )
11. INSTALL TRANSMISSION OIL FILLER TUBE SUB-ASSEMBLY 
    1. Apply ATF WS to a new O-ring, and install it to the transmission oil filler tube sub-assembly.
    2. Install the transmission oil filler tube sub-assembly to the automatic transaxle with the bolt.

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

    3. Install the transmission oil level gauge sub-assembly to the transmission oil filler tube sub-assembly.
       Fig 15: Locating Transmission Oil Filler Tube Sub-Assembly

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
12. INSTALL OIL COOLER TUBE 
    1. Connect the 2 oil cooler hoses to the 2 unions with the 2 hose clamps.
       Fig 16: Locating Oil Cooler Tube And Clamps

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the oil cooler tube to the automatic transaxle with the bolt.

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

13. INSTALL DRIVE PLATE AND TORQUE CONVERTER CLUTCH SETTING BOLT 
    1. Apply a few drops of adhesive to 2 or 3 threads of the 6 torque converter clutch setting bolt tips.

       Adhesive: 

       Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent 

       Fig 17: Applying Adhesive To Threads Of Torque Converter Clutch Setting Bolt Tips

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the 6 torque converter clutch setting bolts while holding the crankshaft pulley bolt with a wrench.

       Torque: 28 N*m (286 kgf*cm, 21 ft.*lbf) 

       NOTE: First install the black colored bolt, and then install the silver colored 5 bolts.
       Fig 18: Locating Torque Converter Clutch Setting Bolts

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
14. INSTALL FLYWHEEL HOUSING UNDER COVER 
    1. Install the flywheel housing under cover to the automatic transaxle.
       Fig 19: Locating Flywheel Housing Under Cover

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
15. INSTALL FRONT ENGINE MOUNTING INSULATOR  (See INSTALLATION )
16. INSTALL REAR ENGINE MOUNTING INSULATOR  (See INSTALLATION )
17. TEMPORARILY INSTALL CENTER ENGINE MOUNTING MEMBER SUB-ASSEMBLY  (See INSTALLATION )
18. INSTALL FRONT SUSPENSION CROSSMEMBER SUB-ASSEMBLY  (See INSTALLATION )
19. REMOVE ENGINE HANGER  (See REMOVAL )
20. INSTALL FRONT DRIVE SHAFT HOLE SNAP RING LH  (See INSTALLATION )
21. INSTALL FRONT DRIVE SHAFT HOLE SNAP RING RH  (See INSTALLATION )
22. INSTALL FRONT DRIVE SHAFT ASSEMBLY LH  (See INSTALLATION )
23. INSTALL FRONT DRIVE SHAFT ASSEMBLY RH  (See INSTALLATION )
24. INSTALL STEERING KNUCKLE WITH AXLE HUB LH  (See INSTALLATION )
25. INSTALL STEERING KNUCKLE WITH AXLE HUB RH 

    HINT:

    Perform the same procedure as the LH side.

26. INSTALL FRONT LOWER SUSPENSION ARM SUB-ASSEMBLY LH  (See INSTALLATION )
27. INSTALL FRONT LOWER SUSPENSION ARM SUB-ASSEMBLY RH 

    HINT:

    Perform the same procedure as the LH side.

28. INSTALL FRONT STABILIZER LINK ASSEMBLY LH  (See INSTALLATION )
29. INSTALL FRONT STABILIZER LINK ASSEMBLY RH 

    HINT:

    Perform the same procedure as the LH side.

30. CONNECT TIE ROD END SUB-ASSEMBLY LH  (See INSTALLATION )
31. CONNECT TIE ROD END SUB-ASSEMBLY RH 

    HINT:

    Perform the same procedure as the LH side.

32. INSTALL FRONT SPEED SENSOR LH  (See INSTALLATION )
33. INSTALL FRONT SPEED SENSOR RH 

    HINT:

    Perform the same procedure as the LH side.

34. INSTALL FRONT AXLE SHAFT NUT LH  (See INSTALLATION )
35. INSTALL FRONT AXLE SHAFT NUT RH 

    HINT:

    Perform the same procedure as the LH side.

36. INSTALL FRONT EXHAUST PIPE ASSEMBLY  (See INSTALLATION )
37. INSTALL NO. 1 STEERING COLUMN HOLE COVER SUB-ASSEMBLY  (See INSTALLATION )
38. INSTALL NO. 2 STEERING INTERMEDIATE SHAFT ASSEMBLY  (See INSTALLATION )
39. INSTALL COLUMN HOLE COVER SILENCER SHEET  (See INSTALLATION )
40. INSTALL WIRE HARNESS AND CONNECTOR 
    1. Install the transmission control cable support to the automatic transaxle with the bolt.

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

       Fig 20: Locating Transmission Control Cable Bracket Bolt

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Connect the clamp onto the transmission control cable support and connect the speed sensor connector to the speed sensor.
    3. Connect the transmission wire connector, park/neutral position switch connector and 2 wire harness clamps.
41. INSTALL TRANSMISSION CONTROL CABLE ASSEMBLY  (See INSTALLATION )
    Fig 21: Locating Park/ Neutral Position Switch Connector And Wire Harness Clamps

    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
42. CONNECT BREATHER HOSE 
    1. Install the breather hose.
       Fig 22: Locating Breather Hose

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
43. INSTALL WIRE HARNESS  (See INSTALLATION )
44. INSTALL BATTERY CARRIER  (See INSTALLATION )
45. INSTALL BATTERY  (See INSTALLATION )
46. INSTALL AIR CLEANER CASE  (See INSTALLATION )
47. INSTALL AIR CLEANER CAP SUB-ASSEMBLY  (See INSTALLATION )
48. TEMPORARILY TIGHTEN HOOD SUB-ASSEMBLY 
    1. Install the hood sub-assembly with the 4 bolts.

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

       Fig 23: Locating Hood Sub-Assembly And Bolts

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the washer hose and 2 washer hose clamps.
       Fig 24: Locating Washer Hose Clamps And Washer Hose

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
49. INSPECT HOOD SUB-ASSEMBLY  (See ON-VEHICLE INSPECTION )
50. ADJUST HOOD SUB-ASSEMBLY 

    (See ADJUSTMENT )

51. INSTALL FRONT WHEELS  (See INSTALLATION )
52. INSTALL OUTER COWL TOP PANEL  (See INSTALLATION )
53. INSTALL WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY  (See INSTALLATION )
54. INSTALL COWL TOP VENTILATOR LOUVER LH  (See INSTALLATION )
55. INSTALL COWL TOP VENTILATOR LOUVER RH  (See INSTALLATION )
56. INSTALL HOOD TO COWL TOP SEAL  (See INSTALLATION )
57. INSTALL FRONT WIPER ARM AND BLADE ASSEMBLY RH  (See INSTALLATION )
58. INSTALL FRONT WIPER ARM AND BLADE ASSEMBLY LH  (See INSTALLATION )
59. INSTALL FRONT WIPER ARM HEAD CAP  (See INSTALLATION )
60. ADD AUTOMATIC TRANSAXLE FLUID 
61. INSPECT TRANSAXLE FLUID LEVEL  (See AUTOMATIC TRANSAXLE FLUID )
62. INSPECT FOR EXHAUST GAS LEAK 
63. INSPECT SHIFT LEVER POSITION  (See ADJUSTMENT )
64. ADJUST SHIFT LEVER POSITION  (See ADJUSTMENT )
65. INSTALL ENGINE UNDER COVER LH 
66. INSTALL ENGINE UNDER COVER RH 
67. INSPECT AND ADJUST FRONT WHEEL ALIGNMENT 

    (See FRONT WHEEL ALIGNMENT )

68. INSTALL NO. 2 CYLINDER HEAD COVER  (See INSTALLATION )
69. CHECK SPEED SENSOR SIGNAL 

    w/o VSC: (See TEST MODE PROCEDURE )

    w/ VSC: (See TEST MODE PROCEDURE )

70. RESET MEMORY 

HINT:

Perform RESET MEMORY (AT initialization) when replacing the automatic transaxle assembly (See MANUAL SHIFTING TEST ).