Automatic Transmission Assembly Installation

Install the transfer to the transmission.

Install the clamp and 8 bolts.

Torque:

24 N*m{244 kgf*cm, 17 ft.*lbf}

Install the transmission control cable bracket with the 2 bolts.

Torque:

28 N*m{286 kgf*cm, 21 ft.*lbf}

Engage the spline of the input shaft turbine runner.

Engage the spline of the stator shaft and the stator while turning the torque converter assembly.

HINT:

If the stator shaft spline are difficult to engage with the stator splines, move the torque converter back approximately 10 mm (0.394 in.) and engage the splines while rotating the torque converter.

Turn the torque converter assembly to insert the key of the oil pump drive gear into the groove of the torque converter assembly.

Clean the torque converter set bolt holes.

Using a vernier caliper and straightedge, measure dimension A between the transaxle contact surface of the engine and the torque converter contact surface of the drive plate.

NOTICE:

Make sure to deduct the thickness of the straightedge.

Using a vernier caliper and straightedge, measure dimension B shown in the illustration and check that dimension B is more than dimension A, which was measured in the previous step.

Standard:

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

NOTICE:

1. Make sure to deduct the thickness of the straightedge.
   
2. If the transaxle is installed to the engine with the torque converter not sufficiently inserted, the torque converter may be damaged.
   

Apply clutch spline grease to the surface of the crankshaft that contacts the torque converter centerpiece.

Clutch spline grease:

Toyota Genuine Clutch Spline Grease or equivalent

Maximum grease amount:

Approximately 1 g (0.0353 oz.)

While keeping the engine and automatic transmission assembly horizontal, align the knock pins with the holes in the automatic transmission assembly and install the 7 bolts shown in the illustration.

Torque:

for bolt A:

71 N*m{724 kgf*cm, 52 ft.*lbf}

for bolt B:

37 N*m{377 kgf*cm, 27 ft.*lbf}

NOTICE:

1. Confirm that the 2 knock pins are installed to the engine cylinder block before installing the transmission.
   
2. Do not use excessive force to pry on the transmission assembly.
   
3. Insert the knock pins into the knock pin holes securely so that the end face of the transmission assembly fits close against the engine assembly before tightening the bolts.
   
4. Check that the torque converter rotates.
   

Install the manifold stay with the 3 bolts.

Torque:

for bolt A:

72 N*m{730 kgf*cm, 53 ft.*lbf}

for bolt B:

44 N*m{449 kgf*cm, 32 ft.*lbf}

for bolt C:

30 N*m{306 kgf*cm, 22 ft.*lbf}

Text in Illustration

	Bolt A
	Bolt B
	Bolt C

Turn the crankshaft to gain access to the installation locations of the 6 torque converter setting bolts and install each bolt while holding the crankshaft pulley bolt with a wrench.

Torque:

41 N*m{418 kgf*cm, 30 ft.*lbf}

NOTICE:

Install the black bolt first, and then the 5 silver bolts.

Install the flywheel housing dust seal.

Connect the park/neutral position switch connector, transmission wire connector, 2 speed sensor connectors and transfer control side connector.

Attach the 5 harness clamps.

Install the heat insulator with the 2 bolts to the park/neutral position switch.

Torque:

7.5 N*m{76 kgf*cm, 66 in.*lbf}

Tilt up the transmission.

Connect the ground cable with the nut.

Torque:

5.5 N*m{56 kgf*cm, 49 in.*lbf}

Install the engine mounting insulator to the transmission with the 4 bolts.

Torque:

47 N*m{479 kgf*cm, 35 ft.*lbf}

Install the No. 3 frame crossmember to the rear engine mounting insulator with the 4 bolts.

Torque:

27 N*m{275 kgf*cm, 20 ft.*lbf}

Install the frame crossmember with the 4 bolts and 4 nuts.

Torque:

50 N*m{510 kgf*cm, 37 ft.*lbf}

Connect the wire harness clamp to the No. 3 frame crossmember.

Connect the control cable with a new clip.

Connect the control cable with the nut.

Torque:

14 N*m{143 kgf*cm, 10 ft.*lbf}

Temporarily install the ends of the oil cooler tubes to the oil cooler tube unions by hand.

Close the 3 No. 2 oil cooler hose clamps and install the 3 bolts.

Torque:

for bolt A:

5.0 N*m{51 kgf*cm, 44 in.*lbf}

for bolt B:

12 N*m{122 kgf*cm, 9 ft.*lbf}

Using a union nut wrench, tighten the inlet and outlet tubes.

Torque:

34 N*m{350 kgf*cm, 25 ft.*lbf}

NOTICE:

Use the formula to calculate special torque values for situations where a union nut wrench is combined with a torque wrench (HILUX_TGN26 RM000004QR1006X.html).

Coat a new O-ring with ATF and install it to the transmission oil filler tube.

Install the transmission oil filler tube with the 2 bolts.

Torque:

12 N*m{122 kgf*cm, 9 ft.*lbf}

Install the transmission oil level dipstick.

Using a vernier caliper, measure the free length of the compression spring.

Minimum length:

40 mm (1.57 in.)

Install the front exhaust pipe to the exhaust pipe support.

Using a plastic-faced hammer and wooden block, tap on a new gasket until its surface is flush with the exhaust manifold.

NOTICE:

1. Be sure to install the gasket so that it faces the correct direction.
   
2. Do not reuse the gasket.
   
3. Do not damage the gasket.
   
4. When connecting the exhaust pipe, do not push in the gasket with the exhaust pipe.
   

Connect the front exhaust pipe to the exhaust manifold with the 2 compression springs and 2 bolts. Alternately tighten the bolts in several passes.

Torque:

43 N*m{438 kgf*cm, 32 ft.*lbf}

While pushing the select return spring to the left with the end of the transfer high and low shift lever, insert the end of the shift lever into the shift fork.

While holding down the shift lever cap, install the snap ring to install the transfer high and low shift lever.

Return the transfer front drive shift boot to its original position.

Install the shift lever boot with the 4 screws.

When moving the shift lever from P to R with the ignition switch ON and the brake pedal depressed, make sure that the shift lever moves smoothly and correctly into position.

Start the engine and make sure that the vehicle moves forward after moving the shift lever from N to D, and moves rearward after shifting to R.
If the results are not as specified, inspect the park/neutral position switch and adjust the shift lever position.

Move the shift lever to N.

Remove the nut and disconnect the control cable.

Turn the control shaft lever clockwise until it stops, and then turn it counterclockwise 2 notches to set it to the N position.

While holding the control shaft lever slightly toward the R position side, connect the cable with the nut.

Torque:

14 N*m{143 kgf*cm, 10 ft.*lbf}