Automatic Transmission Assembly (For 1Gr-Fe) Installation

Attach the 8 wire harness clamps and claw and install the 4 wire harness clamp brackets to the wire harness.

w/o ATF Warmer:
Install the wire harness clamp bracket to the automatic transmission assembly with the bolt.

Torque:

13 N*m{127 kgf*cm, 9 ft.*lbf}

Using a vernier caliper and straightedge, measure the dimension (A) between the automatic transmission assembly contact surface of the engine assembly (*a) and the torque converter assembly contact surface of the drive plate (*b).

Align the matchmark on the automatic transmission case sub-assembly with the one on the torque converter assembly and engage the splines of the input shaft with the turbine runner splines.

NOTICE:

Install the torque converter assembly to the input shaft while keeping it horizontal.

Rotate the torque converter assembly approximately 180° and engage the splines of the stator shaft with the stator assembly.

NOTICE:

1. Do not damage the front oil pump oil seal.
   
2. Install the torque converter assembly to the input shaft while keeping it horizontal.
   

Rotate the torque converter assembly approximately 180° again, align the matchmark on the torque converter assembly with the one on the automatic transmission case sub-assembly and insert the key of the torque converter assembly into the groove of the oil pump drive gear.

NOTICE:

1. Do not push the torque converter assembly excessively when rotating it.
   
2. Do not damage the front oil pump oil seal.
   
3. Install the torque converter assembly to the input shaft while keeping it horizontal.
   

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

Standard distance:

B = A + 1 mm (0.0394 in.) or more

NOTICE:

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

Install the transmission oil pan heat insulator to the automatic transmission assembly with the 3 bolts.

Torque:

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

Install the transmission control cable bracket to the automatic transmission assembly with the 2 bolts.

Torque:

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

Install the transfer assembly with the 8 bolts and bracket.

Torque:

24 N*m{245 kgf*cm, 18 ft.*lbf}

NOTICE:

Take care not to damage the adaptor rear oil seal with the transfer input gear spline.

Temporarily install the transmission oil cooler assembly to the automatic transmission assembly with the bolt labeled A. Install the bolt labeled B and bolt labeled C tighten it to the specified torque. Then tighten the bolt labeled A to the specified torque.

Torque:

21 N*m{214 kgf*cm, 15 ft.*lbf}

Connect the 2 oil cooler hoses to the automatic transmission assembly, and slide the 2 clips to secure them.

NOTICE:

Make sure to install any hose clips without a specific installation direction in a direction that does not interfere with other parts.

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

Clutch spline grease:

Toyota Genuine Clutch Spline Grease or equivalent

Maximum grease amount:

Approximately 1 g (0.0353 oz.)

Text in Illustration

*1	Crankshaft
*2	Torque Converter Assembly Centerpiece
	Clutch Spline Grease

Confirm that the 2 knock pins are installed on the engine assembly and are not damaged.

While keeping the engine assembly and automatic transmission assembly horizontal, align the 2 knock pins with the holes in the automatic transmission assembly and install the 9 bolts.

Torque:

for Bolt A:

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

for Bolt B:

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

NOTICE:

1. Do not use excessive force when installing the automatic transmission assembly.
   
2. Check that the torque converter assembly rotates.
   
3. Make sure that the wire harness or other similar items are not pinched between the contact surfaces.
   
4. Make sure that the cooling fan and fan shroud do not contact the engine assembly when tilting the automatic transmission assembly.
   

Connect the breather hose to the engine assembly.

Tilt down the automatic transmission assembly.

NOTICE:

Make sure that the cooling fan and fan shroud do not contact the engine assembly when tilting the automatic transmission assembly.

Connect the wire harness to the automatic transmission assembly with the 4 bolts.

Torque:

8.0 N*m{82 kgf*cm, 71 in.*lbf}

Attach the 2 wire harness clamps.

Attach the heated oxygen sensor connector to the wire harness clamp bracket.

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

HINT:

Push up the lever until the claw of the transmission wire connector makes a connection sound.

Connect the breather hose to the wire harness.

Install the clamp to the transmission breather bracket.

HINT:

It is not necessary to remove the transmission breather clamp unless it is being replaced.

Install the transmission breather bracket to the automatic transmission assembly with the bolt.

Torque:

6.5 N*m{66 kgf*cm, 58 in.*lbf}

Connect the 2 breather hoses and attach the wire harness clamp to the transmission breather bracket.

Install the rear No. 1 engine mounting insulator to the automatic transmission assembly with the 4 bolts.

Torque:

73 N*m{739 kgf*cm, 53 ft.*lbf}

NOTICE:

Make sure to install the engine mounting heat insulator so that its installation surface faces the right side of the vehicle.

Install the engine mounting heat insulator to the rear No. 1 engine mounting insulator with the bolt.

Torque:

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

Install the No. 3 frame crossmember sub-assembly to the body with the 4 bolts and 4 nuts.

Torque:

72 N*m{734 kgf*cm, 53 ft.*lbf}

NOTICE:

Install the nuts so that they face the rear of the vehicle.

HINT:

Hold the bolts while tightening the nuts.

Connect the No. 3 frame crossmember sub-assembly to the rear No. 1 engine mounting insulator with the 4 bolts.

Torque:

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

Install the front suspension member bracket LH and RH with the 8 bolts.

Torque:

33 N*m{337 kgf*cm, 24 ft.*lbf}

Connect the water by-pass pipe to the automatic transmission assembly with the 2 bolts.

Torque:

21 N*m{214 kgf*cm, 15 ft.*lbf}

Connect the 2 water by-pass hoses to the transmission oil cooler assembly, and slide the 2 clips to secure them.

Connect the 2 oil cooler tubes to the automatic transmission assembly and engine assembly with the 2 bolts.

Torque:

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

Connect the 2 oil cooler hoses to the transmission oil cooler assembly, and slide the 2 clips to secure them.

Connect the ends of the 2 oil cooler tubes to the automatic transmission assembly by hand.

Connect the 2 oil cooler tubes to the automatic transmission assembly and engine assembly with the 2 bolt.

Torque:

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

Using a 17 mm union nut wrench, tighten the 2 oil cooler tubes.

Torque:

Specified tightening torque:

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

HINT:

1. Calculate the torque wrench reading when changing the fulcrum length of the torque wrench.
   (LandCruiser RM000003YMD00TX.html)
   
2. When using a union nut wrench (fulcrum length of 30 mm (1.181 in.)) + torque wrench (fulcrum length of 180 mm (7.087 in.)): 29 N*m (300 kgf*cm, 22 ft.*lbf)
   

w/ ATF Warmer:

1. Install the transmission insulator RH to the automatic transmission assembly with the 2 bolts.
   

   Torque:

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

2. Install the wire harness clamp bracket from the transmission insulator RH with the bolt.
   

   Torque:

   13 N*m{127 kgf*cm, 9 ft.*lbf}

w/o ATF Warmer:

1. Install the transmission insulator RH to the automatic transmission assembly with the 3 bolts.
   

   Torque:

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

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

Move the shift lever to N, and with the cable end lightly pushed toward the rear of the vehicle, install the transmission control cable assembly to the transmission control shaft lever LH with the nut.

Torque:

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

HINT:

Tighten the nut with no slack in the transmission control cable assembly.

Connect the transmission control shift cable assembly to the transmission control cable bracket with a new clip.

Turn the crankshaft to gain access to the installation locations of the 6 drive plate and torque converter assembly setting bolts and install each bolt 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 remaining 5 silver colored bolts.

Install the flywheel housing side cover to the engine assembly.

Fill the transmission with the correct amount of fluid as listed in the table below.

Standard Capacity:

Performed Repair	Engine Type	Fill Amount
Automatic transmission fluid drain and refill	2TR-FE	1.5 liters (1.6 US qts, 1.3 Imp. qts)
	1GD-FTV, 1GR-FE	3.1 liters (3.3 US qts, 2.7 Imp. qts)
Removal and installation of the automatic transmission oil pan sub-assembly	2TR-FE	0.8 liters (0.8 US qts, 0.7 Imp. qts)
	1GD-FTV, 1GR-FE	2.4 liters (2.5 US qts, 2.1 Imp. qts)
Removal and installation of the transmission valve body assembly	2TR-FE	1.6 liters (1.7 US qts, 1.4 Imp. qts)
	1GD-FTV, 1GR-FE	3.1 liters (3.3 US qts, 2.7 Imp. qts)
Removal and installation of the torque converter assembly (Including the oil drain)	2TR-FE	2.4 liters (2.5 US qts, 2.1 Imp. qts)
	1GD-FTV, 1GR-FE	4.2 liters (4.4 US qts, 3.7 Imp. qts)

HINT:

If the specified amount of automatic transmission fluid cannot be added, perform the following:

1. Temporarily install the O-ring and refill plug to the automatic transmission assembly.
   

   HINT:

   Reuse the old O-ring as the refill plug will be removed again.

2. Lower the vehicle.
   

3. Start the engine.
   

   NOTICE:

   To reduce load, make sure that all electrical systems, such as the air conditioning, lighting system, electric fan and audio system, are off.

4. Slowly move the shift lever from P to S, then move the shift lever to P.
   

5. Allow the engine to idle for 30 seconds to warm it up.
   

6. Turn the ignition switch off.
   

7. Remove the refill plug and O-ring from the automatic transmission assembly.
   

8. Fill the automatic transmission assembly with the correct amount of automatic transmission fluid as listed in the table above.
   

9. Temporarily install the O-ring and refill plug to the automatic transmission assembly.
   

   HINT:

   Reuse the old O-ring as the refill plug will be removed again.

Tighten the cylinder block drain cock plug.

Torque:

13 N*m{130 kgf*cm, 9 ft.*lbf}

Tighten the radiator drain cock plug by hand.

Add engine coolant.

Standard Capacity:

Item			Specified Condition
for Automatic Transmission	w/o Warmer	w/o Rear Heater	10.5 liters (11.1 US qts, 9.2 Imp. qts)
		w/ Rear Heater	12.3 liters (13.0 US qts, 10.8 Imp. qts)
	w/ Warmer	w/o Rear Heater	11.0 liters (11.6 US qts, 9.7 Imp. qts)
		w/ Rear Heater	12.8 liters (13.5 US qts, 11.3 Imp. qts)
for Manual Transmission	w/o Rear Heater		10.7 liters (11.3 US qts, 9.4 Imp. qts)
	w/ Rear Heater		12.5 liters (13.2 US qts, 11.0 Imp. qts)

NOTICE:

Do not substitute plain water for engine coolant.

HINT:

1. TOYOTA vehicles are filled with TOYOTA SLLC at the factory. In order to avoid damage to the engine cooling system and other technical problems, only use TOYOTA SLLC or similar high quality ethylene glycol based non-silicate, non-amine, non-nitrite, non-borate coolant with long-life hybrid organic acid technology (coolant with long-life hybrid organic acid technology consists of a combination of low phosphates and organic acids).
   
2. Press the No. 1 and No. 2 radiator hoses several times by hand, and then check the coolant level. If the coolant level is low, add coolant.
   

Slowly pour coolant into the radiator reservoir until it reaches the F line.

Install the reservoir cap.

Install the radiator cap.*1

Start the engine and stop it immediately.*2

Allow approximately 10 seconds to pass. Then remove the radiator cap and check the coolant level. If the coolant level has decreased, add coolant.*3

Repeat steps *1, *2 and *3 until the coolant level does not decrease.

HINT:

Be sure to perform this step while the engine is cold, as air in the No. 1 radiator hose will flow into the radiator if the engine is warmed up and the thermostat opens.

Install the radiator cap.*4

Set the air conditioning as follows.*5

Start the engine, warm it up until the thermostat opens, and then continue to run the engine for several minutes to circulate the coolant.*6

CAUTION:

1. Wear protective gloves. Hot areas on the parts may injure your hands.
   
2. Be careful of the fan.
   
3. Be careful as the engine, radiator and radiator hoses are hot and can cause burns.
   

NOTICE:

1. Immediately after starting the engine, if the radiator reservoir does not have any coolant, perform the following: 1) stop the engine, 2) wait until the coolant has cooled down, and 3) add coolant until the coolant is filled to the F line.
   
2. Do not start the engine when there is no coolant in the radiator reservoir.
   
3. Pay attention to the needle of the engine coolant temperature receiver gauge. Make sure that the needle does not show an abnormally high temperature.
   
4. If there is not enough coolant, the engine may burn out or overheat.
   

HINT:

1. Press the No. 1 and No. 2 radiator hoses several times by hand to bleed air while warming up the engine.
   
2. The thermostat opening timing can be confirmed by pressing the No. 2 radiator hose by hand and checking when the engine coolant starts to flow inside the hose.
   

Stop the engine, wait until the engine coolant cools down to ambient temperature. Then remove the radiator cap and check the coolant level.*7

CAUTION:

Do not remove the radiator cap while the engine and radiator are still hot. Pressurized, hot engine coolant and steam may be released and cause serious burns.

If the coolant level has decreased, add coolant and warm up the engine until the thermostat opens.*8

If the coolant level has not decreased, check that the coolant level in the radiator reservoir is at the F line.
If the coolant level is below the F line, repeat steps *4 through *8.
If the coolant level is above the F line, drain coolant until the coolant level reaches the F line.

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

Make sure that the shifting lever moves smoothly and can be moderately operated.

When starting the engine, make sure that the vehicle moves forward when shifting from N to D and moves rearward when shifting to R.

Fill the radiator with engine coolant, and then attach a radiator cap tester.

Warm up the engine.

Using the radiator cap tester, increase the pressure inside the radiator to 123 kPa (1.3 kgf/cm², 18 psi), and then check that the pressure does not drop.
If the pressure drops, check the hoses, radiator and water pump for leakage. If there are no signs or traces of external engine coolant leakage, check the heater core, cylinder block and head.

Start the engine. Make sure that there are no oil leaks from the areas that were worked on.

Install the rear engine under cover with the 4 bolts.

Torque:

29 N*m{296 kgf*cm, 21 ft.*lbf}

Hook the engine under cover to the vehicle body as shown in the illustration.

Install the 4 bolts.

Torque:

29 N*m{296 kgf*cm, 21 ft.*lbf}

If automatic transmission parts have been replaced, refer to the Parts Replacement Compensation Table to determine if any additional operations are necessary.
(LandCruiser RM000000W7F0R3X.html)