Land Cruiser URJ200 URJ202 GRJ200 VDJ200 - AB60F AUTOMATIC TRANSMISSION / TRANSAXLE

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

If necessary, clean the converter and recheck the 1-way clutch.

Replace the converter if the 1-way clutch still fails the inspection.

Text in Illustration
	Free
	Lock

Determine the condition of the torque converter.

Text in Illustration
*a	Sample showing maximum allowable amount of powder in ATF

If the inspection result of the torque converter satisfies the following conditions, replace the torque converter.

Malfunction

A metallic sound is emitted from the torque converter during the stall test or when the shift lever is moved to N.

The 1-way clutch is free or locks in both directions.

The amount of powder in the ATF is more than the sample shown in the illustration (see the sample).

HINT:

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

Replace the ATF in the torque converter.

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

Clean and check the oil cooler and oil pipe line.

If the torque converter is inspected or the ATF is replaced, clean the oil cooler and oil pipe line.

HINT:

Apply compressed air at 196 kPa (2.0 kgf/cm², 28 psi) into the inlet hose.

If a large amount of powder is found in the ATF, add new ATF using a bucket pump and clean the oil cooler and oil pipe again.

If the ATF is cloudy, inspect the oil cooler.

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

Text in Illustration
*a	Correct
*b	Incorrect
*c	Bottom is damaged

When there is any damage to the end of a bolt for the torque converter and to the bottom of the bolt hole, replace the bolt and the torque converter.

All of the bolts should be the same length.

Bolts with washers must be used.

2. INSTALL TORQUE CONVERTER ASSEMBLY

Engage the splines of the input shaft and turbine runner.

Engage 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 and engage the splines while rotating the torque converter.

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

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

Text in Illustration
*1	Engine Surface
*2	Drive Plate Surface

NOTICE:

Make sure to deduct the thickness of the straightedge.

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

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

NOTICE:

Make sure to deduct the thickness of the straightedge.

If the transaxle is installed to the engine with the torque converter not sufficiently inserted, the torque converter may be damaged.

3. INSTALL WIRE HARNESS CLAMP BRACKET

Automatic Transmission Assembly (For 1Ur-Fe) - Installation. AB60F AUTOMATIC TRANSMISSION / TRANSAXLE. Land Cruiser URJ200 URJ202 GRJ200 VDJ200

Install the 8 bolts and 8 harness clamp brackets.

Torque:
Bolt A:
8.0 N*m{ 82 kgf*cm, 71 in.*lbf}
Bolt B:
29 N*m{ 296 kgf*cm, 21 ft.*lbf}
Bolt C, Type A:
8.0 N*m{ 82 kgf*cm, 71 in.*lbf}
Bolt C, Type B:
12 N*m{ 122 kgf*cm, 9 ft.*lbf}

Text in Illustration
*1	Type A
*2	Type B

NOTICE:

The different marks on the heads of the bolts are shown in the illustration. Check whether the bolt being used is type A or type B, and then tighten the bolt using the appropriate torque.

4. INSTALL TRANSFER ASSEMBLY

Install the transfer with the 8 bolts.

Torque:
40 N*m{ 408 kgf*cm, 30 ft.*lbf}

NOTICE:

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

5. INSTALL LOWER TRANSFER CASE PROTECTOR

Install the lower transfer case protector with the 7 bolts.

Torque:
14 N*m{ 139 kgf*cm, 10 ft.*lbf}

Attach the clamp of the ground cable to the lower transfer case protector.

6. INSTALL TRANSFER BREATHER HOSE SUB-ASSEMBLY

Attach the 3 breather hose clamps to connect the transfer breather hose to the automatic transmission breather tube.

Connect the 2 breather plug hoses to the harness clamp bracket.

7. INSTALL TRANSMISSION OIL COOLER ASSEMBLY (w/ ATF Warmer)

Coat 2 new O-rings with ATF and install them to the transmission oil cooler assembly.

Text in Illustration
*1	Transmission Oil Cooler Assembly
*2	Transmission Oil Thermostat
*3	O-ring

Coat 2 new O-rings with ATF and install them to the transmission oil thermostat.

Temporarily install bolt labeled A. Install the bolts labeled B and tighten them to the specified torque. Then tighten bolt labeled A to the specified torque.

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

8. INSTALL AUTOMATIC TRANSMISSION ASSEMBLY

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.)

Confirm that the 2 knock pins are on the surface of the engine block that contacts the transaxle.

Text in Illustration
*1	Torque Converter Centerpiece
*2	Knock Pin
*3	Crankshaft

Keeping the engine and automatic transaxle assembly horizontal, align the knock pins with the holes on the automatic transaxle assembly and install the 10 bolts shown in the illustration.

Torque:
for 17 mm head bolt A:
71 N*m{ 724 kgf*cm, 52 ft.*lbf}
for 14 mm head bolt B:
37 N*m{ 377 kgf*cm, 27 ft.*lbf}

9. CONNECT TRANSMISSION OIL COOLER HOSE (w/ ATF Warmer)

Connect the 2 transmission oil cooler hoses to the transmission oil thermostat as shown in the illustration.

Text in Illustration
*a	Paint Mark
*b	White Paint
*c	Yellow Paint
*d	Upper
*e	-45 to 45°

CAUTION:

Make sure the pinching portion of each clip is facing the direction shown in the illustration.

Make sure the paint mark of each hose is facing outward.

10. CONNECT NO.2 WATER BY-PASS PIPE (w/ ATF Warmer)

Connect the 2 water by-pass hoses with the 2 clips and install the No. 2 water by-pass pipe with the bolt as shown in the illustration.

Text in Illustration
*1	Claw
*a	Paint Mark
*b	Green Paint Mark
*c	White Paint Mark
*d	Upper

Torque:
18 N*m{ 184 kgf*cm, 13 ft.*lbf}

NOTICE:

Make sure the pinching portion of each clip is facing the direction shown in the illustration.

Make sure the paint mark of each hose is facing outward.

11. CONNECT TRANSMISSION OIL COOLER HOSE (w/o ATF Warmer)

Connect the 2 transmission oil cooler hoses to the oil cooler tube unions.

Text in Illustration
*a	Paint Mark
*b	Yellow Paint
*c	White Paint
*d	Upper
*e	-45 to 45°

NOTICE:

Make sure the pinching portion of each clip is facing the direction shown in the illustration.

Make sure the paint mark of each hose is facing outward.

12. CONNECT WIRE HARNESS AND CONNECTOR

Automatic Transmission Assembly (For 1Ur-Fe) - Installation. AB60F AUTOMATIC TRANSMISSION / TRANSAXLE. Land Cruiser URJ200 URJ202 GRJ200 VDJ200

Connect the park/neutral position switch connector, 2 transmission wire connectors, 2 speed sensor connectors and 3 transfer control connectors.

HINT:

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

Attach the 4 connector clamps and 11 harness clamps.

Install the 4 wire harness clamps.

Tilt up the automatic transmission.

Connect the ground cable with the bolt.

Torque:
8.4 N*m{ 86 kgf*cm, 74 in.*lbf}

13. INSTALL REAR NO. 1 ENGINE MOUNTING INSULATOR

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

Torque:
59 N*m{ 602 kgf*cm, 44 ft.*lbf}

Install the engine mounting heat insulator with the 2 bolts.

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

14. INSTALL NO. 3 FRAME CROSSMEMBER SUB-ASSEMBLY

Install the frame crossmember to the rear engine mounting insulator with the 4 bolts.

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

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

Torque:
110 N*m{ 1122 kgf*cm, 81 ft.*lbf}

Install the engine mounting hole cover.

15. INSTALL DRIVE PLATE AND TORQUE CONVERTER SETTING BOLT

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

Torque:
53 N*m{ 535 kgf*cm, 39 ft.*lbf}

NOTICE:

First install the black-colored bolt, and then the remaining 5 silver colored bolts.

16. INSTALL STARTER ASSEMBLY

Install the flywheel housing side cover.

Install the starter with the 2 bolts.

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

Install the starter wire with the nut.

Torque:
9.8 N*m{ 100 kgf*cm, 87 in.*lbf}

Connect the starter connector.

17. INSTALL STARTER COVER

Install the starter cover with the 3 bolts.

Torque:
12 N*m{ 117 kgf*cm, 8 ft.*lbf}

18. INSTALL EXHAUST MANIFOLD SUB-ASSEMBLY RH

w/ Secondary Air Injection System:

Install a new gasket to the No. 3 air tube.

HINT:

Install the gasket with the claws of the gasket facing the tube.

Install a new gasket to the cylinder head.

Text in Illustration
*1	Tab
*a	Front

HINT:

Install the gasket with the gasket tab facing toward the front of the engine.

w/ Secondary Air Injection System:

Install the exhaust manifold to the cylinder head with the 7 new nuts labeled A.

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

Install the exhaust manifold to the No. 3 air tube with the 2 nuts labeled B.

Torque:
10 N*m{ 102 kgf*cm, 7 ft.*lbf}

w/o Secondary Air Injection System:

Install the exhaust manifold with 7 new nuts.

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

Connect the air fuel ratio sensor connector and attach the wire harness clamp.

19. INSTALL NO. 1 EXHAUST MANIFOLD HEAT INSULATOR

Install the heat insulator with 3 new bolts.

Torque:
10 N*m{ 102 kgf*cm, 7 ft.*lbf}

20. INSTALL ENGINE OIL LEVEL DIPSTICK GUIDE

Apply engine oil to a new O-ring, and then install the O-ring to the engine oil level dipstick guide.

Install the engine oil level dipstick guide with the bolt.

Torque:
10 N*m{ 102 kgf*cm, 7 ft.*lbf}

Attach the engine wire clamp.

Install the engine oil level dipstick.

21. INSTALL NO. 2 MANIFOLD STAY

Temporarily install the manifold stay with the 3 bolts.

Tighten the 3 bolts in the sequence shown in the illustration.

Torque:
40 N*m{ 408 kgf*cm, 30 ft.*lbf}

22. INSTALL MANIFOLD STAY

Temporarily install the manifold stay with the 3 bolts.

Tighten the 3 bolts in the sequence shown in the illustration.

Torque:
40 N*m{ 408 kgf*cm, 30 ft.*lbf}

23. INSTALL EXHAUST PIPE

()

24. INSTALL PROPELLER SHAFT ASSEMBLY

()

25. INSTALL FRONT PROPELLER SHAFT ASSEMBLY

()

26. CONNECT FLOOR SHIFT GEAR SHIFTING ROD SUB-ASSEMBLY

Connect the gear shifting rod to the transmission control shaft lever RH with the pin and a new clip.

27. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

NOTICE:

When disconnecting the cable, some systems need to be initialized after the cable is reconnected ().

28. ADD AUTOMATIC TRANSMISSION FLUID

()

29. ADD ENGINE COOLANT

Add engine coolant.

Standard Capacity:
Item Specified Condition
with rear heater 16.2 liters (17.1 US qts, 14.3 Imp. qts)
without rear heater 13.4 liters (14.2 US qts, 11.8 Imp. qts)

NOTICE:

Do not substitute plain water for engine coolant.

HINT:

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).

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

Install the reservoir cap.

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.

Install the radiator cap.

Start the engine and warm it up until the thermostat opens.

HINT:

The thermostat opening timing can be confirmed by pressing the radiator inlet hose by hand, and checking when the engine coolant starts to flow inside the hose.

Maintain the engine speed at 2000 to 2500 rpm.

NOTICE:

Make sure that the radiator reservoir still has some coolant in it.

Pay attention to the needle of the water temperature meter. Make sure that the needle does not show an abnormally high temperature.

If there is not enough coolant, the engine may burn out or overheat.

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.

Run the engine at 2000 rpm until the coolant level has stabilized.

Press the No. 1 and No. 2 radiator hoses several times by hand to bleed air.

CAUTION:

Wear protective gloves.

Be careful as the radiator hoses are hot.

Keep your hands away from the fan.

Stop the engine, and wait until the engine coolant cools down to ambient temperature.

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.

Check that the coolant level is between the F and L lines.

If the coolant level is below the L line, repeat all of the procedures above.

If the coolant level is above the F line, drain coolant so that the coolant level is between the F and L lines.

30. INSPECT FOR ENGINE COOLANT LEAK

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.

Fill the radiator with coolant and 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 check that the pressure does not drop.

If the pressure drops, check the hoses, radiator and water pump for leaks. If no external leaks are found, check the heater core, cylinder block and head.

31. INSPECT SHIFT LEVER POSITION

When moving the shift lever from P to R with the engine switch on (IG) and the brake pedal depressed, make sure that it moves smoothly and correctly into position.

Check that the shift lever does not stop when moving the shift lever from R to P, and check that the shift lever does not stick when moving the shift lever from D to S.

Start the engine and make sure that the vehicle moves forward after moving the shift lever from N to D, and moves rearward after moving the shift lever to R.

If there are problems during the above inspections, perform the adjustment using the following procedures.

Move the shift lever to N

Loosen the nut of the floor shift gear shifting rod. Then, with the lever of the floor shift assembly lightly pushed towards the rear of the vehicle, tighten the nut.

Torque:
13 N*m{ 133 kgf*cm, 10 ft.*lbf}

Text in Illustration
*1	Lever

32. INSPECT FOR EXHAUST GAS LEAK

33. INSTALL FRONT FENDER APRON TRIM PACKING C

Install the front fender apron trim packing C with the 4 clips.

34. INSTALL FRONT FENDER APRON TRIM PACKING A

Install the front fender apron trim packing A with the 3 clips.

35. INSTALL OIL PAN PROTECTOR ASSEMBLY

Install the oil pan protector with the 4 bolts.

Torque:
63 N*m{ 642 kgf*cm, 46 ft.*lbf}

36. INSTALL NO. 2 ENGINE UNDER COVER

Install the No. 2 engine under cover with the 2 bolts.

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

37. INSTALL NO. 1 ENGINE UNDER COVER

Install the No. 1 engine under cover sub-assembly with the 10 bolts.

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

38. INSTALL FRONT FENDER SPLASH SHIELD SUB-ASSEMBLY LH

Push in the clip to install the front fender splash shield sub-assembly LH.

Install the 3 bolts and screw.

39. INSTALL FRONT FENDER SPLASH SHIELD SUB-ASSEMBLY RH

Push in the clip to install the front fender splash shield sub-assembly RH.

Install the 3 bolts and 2 screws.

40. RESET MEMORY

Perform the Reset Memory procedures (A/T initialization) ().

Item	Specified Condition
with rear heater	16.2 liters (17.1 US qts, 14.3 Imp. qts)
without rear heater	13.4 liters (14.2 US qts, 11.8 Imp. qts)