Automatic Transaxle ASSY: Replacement

REMOVE ENGINE ASSEMBLY WITH TRANSAXLE (See ENGINE MECHANICAL )
REMOVE FRONT DRIVE SHAFT ASSY RH (See REMOVAL, OVERHAUL & INSTALLATION )
REMOVE FRONT DRIVE SHAFT ASSY LH (See REMOVAL, OVERHAUL & INSTALLATION )
REMOVE TRANSMISSION CONTROL CABLE BRACKET NO. 2
1. Remove the bolt and transmission control cable bracket No.2.
  
  Fig 1: Removing Transmission Control Cable Bracket 2 Bolt
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE WIRE HARNESS CLAMP
1. Disconnect the wire harnesses from the clamps.
2. Remove the 2 bolts and 2 clamps.
  
  Fig 2: Removing Wire Harness Clamp
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
DISCONNECT WIRE HARNESS
1. Remove the bolt and wire harness.
  
  Fig 3: Disconnecting Wire Harness
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE STARTER ASSY
1. Disconnect the connector.
2. Remove the 2 bolts and starter assy.
  
  Fig 4: Removing Starter Assy
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
DISCONNECT CONNECTOR
1. Disconnect the 2 transmission wire connectors.
2. Disconnect the park/neutral position switch connector.
3. Disconnect the 2 speed sensor connectors.
  
  Fig 5: Disconnecting Connector
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE TRANSMISSION CONTROL CABLE BRACKET NO.1
1. Remove the bolt and oil cooler tube clamp.
2. Remove the 2 bolts and transmission control cable bracket No. 1.
  
  Fig 6: Removing Transmission Control Cable Bracket No. 1
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE TRANSMISSION OIL FILLER TUBE SUB-ASSY
1. Remove the ATF level gauge.
2. Disconnect the vent hose from the oil filler tube.
  
  Fig 7: Disconnecting Vent Hose From Oil Filler Tube
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Remove the bolt and oil filler tube.
4. Remove the O-ring from the oil filler tube.
  
  Fig 8: Removing Oil Filler Tube
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE OIL COOLER INLET TUBE NO.1
1. Using SST and spanner, disconnect the oil cooler inlet tube No. 1.
  1. SST 09023-12700
  Fig 9: Disconnecting Oil Cooler Inlet Tube No. 1
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE OIL COOLER OUTLET TUBE NO.1
1. Using SST and spanner, disconnect the oil cooler outlet tube No. 1.
  1. SST 09023-12700
REMOVE TRANSVERSE ENGINE MOUNTING BRACKET
1. Remove the 3 bolts and engine mounting bracket FR.
  
  Fig 10: Removing Transverse Engine Mounting Bracket
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE EXHAUST PIPE SUPPORT BRACKET SUB-ASSY
1. Remove the 2 bolts and nut.
2. Remove the exhaust pipe support bracket and exhaust pipe support bracket No. 1 from the automatic transaxle.
  
  Fig 11: Removing Exhaust Pipe Support Bracket Sub-Assy
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE AUTOMATIC TRANSAXLE ASSY
1. Turn the crankshaft to gain access and remove the 6 bolts while holding the crankshaft pulley bolt with a wrench.
  
  Fig 12: Locating Crankshaft Pulley Bolt
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Remove the 9 bolts.
3. Separate and remove the automatic transaxle.
  
  Fig 13: Removing Automatic Transaxle
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE TORQUE CONVERTER CLUTCH ASSY
INSPECT TORQUE CONVERTER CLUTCH ASSY (See TORQUE CONVERTER CLUTCH AND DRIVE PLATE )
1. SST 09350-32014 (09351-32010, 09351-32020)
INSTALL TORQUE CONVERTER CLUTCH ASSY
1. Install the torque converter clutch to the automatic transaxle.
2. Using vernier calipers, measure the dimension "A" between the transaxle fitting part and the converter fitting part of the drive plate.
  
  Fig 14: Measuring Dimension Between Transaxle Fitting Part And Converter Fitting Part Of Drive Plate
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Using vernier calipers and a straight edge, measure the dimension "B" shown in the illustration and check that "B" is greater than "A" measured in (b).
  1. Standard: A + 1 mm or more
  NOTE: Do not add the thickness of straight edge.
  
  Fig 15: Measuring Converter Installed Dimension
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL AUTOMATIC TRANSAXLE ASSY
1. Install the automatic transaxle and 9 bolts to the engine.
  1. Torque:
  2. Bolt A: 64 N.m (650 kgf.cm, 47 ft.lbf)
  3. Bolt B: 46 N.m (470 kgf.cm, 34 ft.lbf)
  4. Bolt C: 44 N.m (449 kgf.cm, 32 ft.lbf)
2. Apply a few drops of adhesive to each of 2 threads on the tip of the 6 torque converter clutch mounting bolts.
  1. Adhesive: Part No. 08833-00070, THREE BOND 1324 or equivalent
  Fig 16: Installing Automatic Transaxle
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Install the 6 torque converter clutch mounting bolts.
  1. Torque: 41 N.m (420 kgf.cm, 30 ft.lbf)
  HINT:
  
  First install green colored bolt and then the 5 bolts.
  
  Fig 17: Installing Torque Converter Clutch Mounting Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL EXHAUST PIPE SUPPORT BRACKET SUB-ASSY
1. Install the exhaust pipe support bracket and exhaust pipe support bracket No. 1 to the automatic transaxle with the 2 bolts and nut.
  1. Torque:
  2. Bolt: 7.8 N.m (80 kgf.cm, 69 in..lbf)
  3. Nut : 21 N.m (214 kgf.cm, 16 ft.lbf)
  Fig 18: Installing Exhaust Pipe Support Bracket Sub-Assy
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL TRANSVERSE ENGINE MOUNTING BRACKET
1. Install the engine mounting bracket FR and 3 bolts to the automatic transaxle.
  1. Torque: 64 N.m (653 kgf.cm, 47 ft.lbf)
  Fig 19: Installing Transverse Engine Mounting Bracket
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL TRANSMISSION OIL FILLER TUBE SUB-ASSY
1. Coat a new O-ring with ATF, and install them to the oil filler tube.
2. Install the oil filler tube and bolt to the automatic transaxle.
  1. Torque: 5.5 N.m (56 kgf.cm, 49 in..lbf)
  Fig 20: Installing Oil Filler Tube And Bolt To Automatic Transaxle
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Connect the breather hose clamp to the oil filler tube.
4. Install the ATF level gauge.
  
  Fig 21: Connecting Breather Hose Clamp To Oil Filler Tube
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL TRANSMISSION CONTROL CABLE BRACKET NO.1
1. Install the control cable bracket No. 1 and 2 bolts.
  1. Torque: 11.8 N.m (122 kgf.cm, 9 ft.lbf)
INSTALL OIL COOLER INLET TUBE NO.1
1. Temporarily install the oil cooler outlet tube No. 1.
2. Temporarily install the oil cooler inlet tube No. 1.
  
  Fig 22: Installing Transmission Control Cable Bracket No. 1
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Install the oil cooler tube clamp and bolt.
  1. Torque: 5.4 N.m (56 kgf.cm, 49 in..lbf)
  HINT:
  
  Install them so that the oil cooler tube cushion is positioned as illustrated.
  
  Fig 23: Installing Oil Cooler Inlet Tube No. 1
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Using SST and spanner, tighten the oil cooler inlet tube No. 1.
  1. SST 09023-12700
  2. Torque: 34.3 N.m (350 kgf.cm, 25 ft.lbf)
  Fig 24: Tightening Oil Cooler Inlet Tube 1
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL OIL COOLER OUTLET TUBE NO.1
1. Using SST and spanner, tighten the oil cooler outlet tube No. 1.
  1. SST 09023-12700
  2. Torque: 34.3 N.m (350 kgf.cm, 25 ft.lbf)
CONNECT CONNECTOR
1. Connect the 2 transmission with connectors.
2. Connect the park/neutral position switch connector.
3. Connect the 2 speed sensor connectors.
  
  Fig 25: Connecting Connectors
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL STARTER ASSY
1. Install the starter assy and 2 bolts.
  1. Torque: 37 N.m (377 kgf.cm, 27 ft.lbf)
2. Connect the connector.
  
  Fig 26: Installing Starter Assy
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL WIRE HARNESS
1. Install the wire harness and bolt.
  1. Torque: 25.5 N.m (260 kgf.cm, 19 ft.lbf)
  Fig 27: Installing Wire Harness
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL WIRE HARNESS CLAMP
1. Install the 2 clamps and 2 bolts.
  1. Torque: 8.4 N.m (86 kgf.cm, 74 in..lbf)
2. Connect the wire harnesses to the clamps.
  
  Fig 28: Installing Wire Harness Clamp
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL TRANSMISSION CONTROL CABLE BRACKET NO. 2
1. Install the transmission control cable bracket No. 2 and bolt.
  1. Torque: 11.8 N.m (122 kgf.cm, 9 ft.lbf)
  Fig 29: Installing Transmission Control Cable Bracket No. 2
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL FRONT DRIVE SHAFT ASSY LH (See REMOVAL, OVERHAUL & INSTALLATION )
INSTALL FRONT DRIVE SHAFT ASSY RH (See REMOVAL, OVERHAUL & INSTALLATION )
INSTALL ENGINE ASSEMBLY WITH TRANSAXLE (See ENGINE MECHANICAL )