Automatic Transmission Assembly (For 1Kd-Ftv) Installation

Inspect the 1-way clutch.

1. Install SST to the inner race of the 1-way clutch.
   

   SST

   09350-32014(09351-32020)
   

2. Press on the serrations of the starter with a finger and rotate it.
   Check if it rotates smoothly when turned clockwise and locks when turned counterclockwise.
   

   Text in Illustration

   	Free
   	Lock

   If the results are not as specified, clean the converter and recheck the 1-way clutch. If the results still are not as specified, replace the torque converter clutch assembly.
   

Determine the condition of the torque converter clutch.

1. Check that the following conditions are met:
   

   1. During the stall test or when the shift lever is in N, metallic sounds are not emitted from the torque converter clutch.
      
   2. The 1-way clutch turns in one direction and locks in the other direction.
      
   3. The amount of powder in the ATF is not more than the sample shown in the illustration.
      
   If the results are not as specified, replace the torque converter clutch assembly.
   

   HINT:

   The sample illustration shows approximately 0.025 liters (0.026 US qts, 0.022 Imp. qts) of ATF taken from a removed torque converter clutch.

Replace the ATF in the torque converter clutch.

1. AT If the ATF is discolored and/or has a foul odor, stir the ATF in the torque converter clutch thoroughly and drain the ATF with the torque converter facing upward.
   

Prevent deformation of the torque converter clutch and damage to the oil pump gear.

1. When any marks due to interference are found on the end of the bolt for the torque converter clutch and on the bottom of the bolt hole, replace the bolt and torque converter clutch.
   

2. All of the bolts should be the same length.
   

3. Make sure no spring washers are missing.
   

Attach the splines of the input shaft and turbine runner.

Attach the splines of the stator shaft and stator while turning the torque converter assembly.

HINT:

If the stator shaft splines are difficult to engage with the stator splines, move the torque converter back approximately 10 mm (0.393 in.) and engage the splines while rotating the torque converter assembly.

Turn the torque converter to engage the key of the oil pump drive gear with the slot on the torque converter assembly.

Using a vernier caliper and straightedge, measure dimension A between the transmission 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.
   

Install the transfer to the transmission.

Install the clamp and 8 bolts.

Torque:

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

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 1.0 g (0.0353 oz)

Install the transmission to the engine with the 5 bolts.

Torque:

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

NOTICE:

Confirm that the 2 knock pins are installed to the surface of the engine cylinder block that contacts the transmission before installing the transmission.

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

Torque:

48 N*m{489 kgf*cm, 35 ft.*lbf}

NOTICE:

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

Install the No. 2 end plate.

Install the No. 4 cylinder block insulator.

Install the stiffener plate LH to the engine and transmission with the 4 bolts.

Torque:

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

Install the stiffener plate RH (with oil cooler tube clamp) to the engine and transmission with the 4 bolts.

Torque:

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

Connect the 8 connectors and attach the 7 clamps.

Connect the wire harness to the automatic transmission housing with the bolt.

Torque:

13 N*m{128 kgf*cm, 9 ft.*lbf}

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}

Connect the ends of the frame crossmember to the vehicle with the 4 bolts and 4 nuts.

Torque:

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

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

Torque:

17 N*m{173 kgf*cm, 13 ft.*lbf}

Install the control cable bracket with the 2 bolts.

Torque:

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

Move the shift lever to N.

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

Connect the transmission control cable to the transmission control cable bracket with a new clip, and then connect the cable end to the control shaft lever with the nut.

Torque:

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

Connect the end of the inlet oil cooler tube to the automatic transmission by hand.

Connect the end of the outlet oil cooler tube to the automatic transmission by hand.

Install the 3 clamps with the 3 bolts.

Torque:

for bolt A and B:

5.0 N*m{50 kgf*cm, 43 in.*lbf}

for bolt C:

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

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

Torque:

34 N*m{346 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).

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.

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}

Add transfer oil until the oil level is within 5 mm (0.196 in.) from the bottom of the transmission filler plug opening.

Install a new gasket to the filler plug, and then install the plug.

Torque:

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

NOTICE:

1. When adding transfer oil, make sure the vehicle is level.
   
2. An excessively large or small amount of oil may cause problems.
   
3. After adding oil, drive the vehicle and recheck the oil level.
   

Inspect for transfer oil leaks.

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 the R.
If the results are not as specified, inspect the park/neutral position switch and check the shift lever.