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Automatic Transmission ASSY: Replacement

WARNING: This page is about a different car, the 2004 Lexus LS 430. However, it is still accessible from the selected car via links, so may be relevant.
  1. DISCONNECT BATTERY NEGATIVE TERMINAL 
  2. REMOVE ENGINE UNDER COVER NO. 1 
  3. REMOVE ENGINE UNDER COVER NO. 2 
  4. REMOVE INSTRUMENT PANEL UNDER COVER SUB-ASSY NO. 2 (SEE  REPLACEMENT  ) 
  5. REMOVE INSTRUMENT PANEL GARNISH SUB-ASSY LH (SEE  REPLACEMENT  ) 
  6. REMOVE INSTRUMENT PANEL FINISH PANEL (SEE  REPLACEMENT  ) 
  7. REMOVE INSTRUMENT PANEL UNDER COVER SUB-ASSY NO. 1 (SEE  REPLACEMENT  ) 
  8. REMOVE SWITCH BRACE HOLE COVER (SEE  REPLACEMENT  ) 
  9. REMOVE INSTRUMENT PANEL SAFETY PAD SUB-ASSY NO. 1 (SEE  REPLACEMENT  ) 
  10. REMOVE INSTRUMENT PANEL CUP HOLDER ASSY (SEE  REPLACEMENT  ) 
  11. REMOVE CONSOLE UPPER REAR PANEL SUB-ASSY (SEE  REPLACEMENT  ) 
  12. REMOVE CONSOLE BOX CARPET (SEE  REPLACEMENT  ) 
  13. REMOVE REAR CONSOLE ARMREST ASSY (SEE  REPLACEMENT  ) 
  14. REMOVE INSTRUMENT PANEL FINISH PANEL LOWER CENTER (SEE  REPLACEMENT  ) 
  15. REMOVE INSTRUMENT CLUSTER FINISH PANEL SUB-ASSY CENTER (SEE  REPLACEMENT  ) 
  16. REMOVE CONSOLE PANEL SUB-ASSY UPPER (SEE  REPLACEMENT  ) 
  17. REMOVE CONSOLE BOX (SEE  REPLACEMENT  ) 
  18. SEPARATE OXYGEN SENSOR (SEE  REPLACEMENT  ) 
    1. Separate the 2 heated oxygen sensors.
  19. REMOVE FRONT FLOOR BRACE CENTER (SEE  REPLACEMENT  ) 
  20. REMOVE EXHAUST PIPE ASSY (SEE  REPLACEMENT  ) 
  21. REMOVE FRONT FLOOR HEAT INSULATOR NO. 1 (SEE  OVERHAUL  ) 
  22. REMOVE PROPELLER W/CENTER BEARING SHAFT ASSY (SEE  OVERHAUL  ) 

    SST 0992-10010

  23. DRAIN AUTOMATIC TRANSMISSION FLUID 
    1. Remove the drain plug, gasket and drain the ATF.
    2. Install a new gasket and the drain plug.

      Torque: 20 N.m (205 kgf.cm, 15 ft.lbf) 

  24. REMOVE EXHAUST PIPE NO. 1 SUPPORT BRACKET SUB-ASSY 
    1. Remove the 2 bolts and exhaust pipe No. 1 support bracket sub-assy.
      Fig 1: Removing Bolts And Exhaust Pipe No. 1 Support Bracket Sub-Assy
      G01028853Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  25. SEPARATE OIL COOLER INLET TUBE NO. 1 
    1. Remove the 2 bolts and clamps.
      Fig 2: Removing Bolts And Clamps
      G01028854Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Loosen the union nut and separate the oil cooler inlet tube No. 1.
  26. SEPARATE OIL COOLER OUTLET TUBE NO. 1 
    1. Loose the union nut and separate the oil cooler outlet tube No. 1
      Fig 3: Loosing Union Nut And Separate Oil Cooler Outlet Tube No. 1
      G01028855Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  27. SEPARATE FLOOR SHIFT GEAR SHIFTING ROD SUB-ASSY 
    1. Remove the nut and separate the floor shift gear shifting rod.
  28. SUPPORT AUTOMATIC TRANSMISSION ASSY 
    1. Support the automatic transmission assy with a transmission jack.
  29. REMOVE ENGINE REAR MOUNTING MEMBER 
    1. Remove the 4 bolts and separate the engine rear mounting member.
      Fig 4: Removing Bolts And Separate Engine Rear Mounting Member
      G01028856Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the 4 nuts and engine rear mounting member.
      Fig 5: Removing Nuts And Engine Rear Mounting Member
      G01028857Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  30. DISCONNECT CONNECTOR 
    1. Tilt down the automatic transmission.
      NOTE: Take care so that the cooling fan does not come into contact with the fan shroud.
    2. Disconnect the park/neutral position switch connector.
    3. Disconnect the transmission wire connector.
    4. Disconnect the 2 speed sensor connectors.
  31. DISCONNECT WIRE HARNESS 
    1. Remove the 5 bolts and wire harness clamps.
    2. Separate the wire harness from the automatic transmission assy.

      HINT:

      Bolt (a) is tightened to the transmission housing.

      Fig 6: Disconnecting 2 Speed Sensor Connectors
      G01028858Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  32. REMOVE FLYWHEEL HOUSING UNDER COVER 
    1. Remove the 2 bolts and flywheel housing under cover.
      Fig 7: Removing Bolts And Flywheel Housing Under Cover
      G01028859Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  33. REMOVE AUTOMATIC TRANSMISSION ASSY 
    1. Turn the crankshaft to gain access to each bolt.
    2. Hold the crankshaft pulley nut with a wrench and remove the 6 bolts.
      Fig 8: Removing Bolts
      G01028860Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Remove the 9 bolts.
    4. Separate and remove the automatic transmission assy.

      HINT:

      • Bolt (a) is tightened to the transmission housing.
      • At the time of installation, lift the engine front side as shown in illustration (A).
        Fig 9: Removing Bolts
        G01028861Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        Fig 10: Lifting Engine Front Side
        G01028862Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  34. REMOVE ENGINE MOUNTING INSULATOR REAR NO.1 
    1. Remove the 4 bolts and engine mounting insulator rear No. 1.
      Fig 11: Removing Bolts And Engine Mounting Insulator Rear No. 1
      G01028863Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  35. REMOVE TRANSMISSION CONTROL SHAFT LEVER RH 
    1. Remove the nut and transmission control shaft lever RH.
      Fig 12: Removing Nut And Transmission Control Shaft Lever RH
      G01028864Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  36. REMOVE TORQUE CONVERTER CLUTCH ASSY 
    1. Put matchmarks on the transmission case and torque converter clutch assy.
    2. Remove the torque converter clutch assy from the automatic transmission assy.
      Fig 13: Removing Torque Converter Clutch Assy From Automatic Transmission Assy
      G01028865Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  37. INSPECT TORQUE CONVERTER CLUTCH ASSY (SEE  TORQUE CONVERTER CLUTCH ASSY  ) 

    SST 09350-32014 (09351-32010, 09351-32020)

  38. INSTALL TORQUE CONVERTER CLUTCH ASSY 
    1. Using calipers and a straight edge, measure dimension A between the transmission and the end surface of the drive plate.
      Fig 14: Measuring Dimension Between Transmission And End Surface Of Drive Plate
      G01028866Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Aligning the matchmarks on the transmission case and torque converter clutch assy, engage the splines of the input shaft and turbine runner.
      Fig 15: Aligning Matchmarks On Transmission Case And Torque Converter Clutch Assy
      G01028867Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Engage the splines of the stator shaft and stator while turning the torque converter clutch assy.

      HINT:

      Turn the torque converter clutch assy approximately 180°.

      Fig 16: Engaging Splines Of Stator Shaft And Stator
      G01028868Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Turn the torque converter clutch assy and align the matchmarks on the torque converter clutch assy and transmission case to engage the key of the oil pump drive gear into the slot on the torque converter clutch assy.
      NOTE: Do not push on the torque converter when aligning the matchmarks.
      Fig 17: Aligning Matchmarks On Torque Converter Clutch Assy And Transmission Case
      G01028869Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Using calipers and a straight edge, measure the dimension B shown in the illustration and check that B is greater than A measured in step (a).
      Fig 18: Measuring Dimension
      G01028870Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  39. INSTALL TRANSMISSION CONTROL SHAFT LEVER RH 
    1. Install the transmission control shaft lever RH with the nut.

      Torque: 16 N.m (160 kgf.cm, 12 ft.lbf) 

      Fig 19: Installing Transmission Control Shaft Lever RH With Nut
      G01028871Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  40. INSTALL ENGINE MOUNTING INSULATOR REAR NO. 1 
    1. Install the engine mounting insulator rear No. 1 with the 4 bolts.

      Torque: 12 N.m (122 kgf.cm, 9 ft.lbf) 

      Fig 20: Installing Engine Mounting Insulator Rear No. 1 With 4 Bolts
      G01028872Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  41. INSTALL AUTOMATIC TRANSMISSION ASSY 
    1. Install the automatic transmission assy to the engine with the 9 bolts.

      Torque: 

      Bolt A: 14 mm head bolt: 37 N.m (380 kgf.cm, 27 ft.lbf) 

      Bolt: B: 17 mm head bolt: 71 N.m (724 kgf.cm, 52 ft.lbf) 

      HINT:

      • Bolt (a) is tightened to the wire harness clamp.
        Fig 21: Installing Automatic Transmission Assy To Engine With 9 Bolts
        G01028873Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the 6 torque converter clutch mounting bolts.

      Torque: 48 N.m (490 kgf.cm, 35 ft.lbf) 

      HINT:

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

      Fig 22: Installing Torque Converter Clutch Mounting Bolts
      G01028874Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  42. INSTALL FLYWHEEL HOUSING UNDER COVER 
    1. Install the fly wheel housing under cover with the 2 bolts.

      Torque: 18 N.m (184 kgf.cm, 13 ft.lbf) 

      Fig 23: Installing Fly Wheel Housing Under Cover With 2 Bolts
      G01028875Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  43. INSTALL WIRE HARNESS 
    1. Install the wire harness clamps with the 5 bolts.

      Torque: 

      Bolt (a): 68 N.m (694 kgf.cm, 51 ft.lbf) 

      Bolt (b): 7.5 N.m (76 kgf.cm, 66 in.lbf) 

      HINT:

      Bolt (a) is tightened to the transmission housing.

      Fig 24: Installing Wire Harness Clamps With 5 Bolts
      G01028876Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  44. INSTALL ENGINE REAR MOUNTING MEMBER 
    1. Install the engine rear mounting member with the 4 nuts.

      Torque: 12 N.m (122 kgf.cm, 9 ft.lbf) 

      Fig 25: Installing Engine Rear Mounting Member With 4 Nuts
      G01028877Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the engine rear mounting member with the 4 bolts.

      Torque: 26 N.m (270 kgf.cm, 20 ft.lbf) 

      Fig 26: Installing Engine Rear Mounting Member With 4 Bolts
      G01028878Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  45. CONNECT FLOOR SHIFT GEAR SHIFTING ROD SUB-ASSY 
    1. Connect the floor shift gear shifting rod sub-assy with the nut.

      Torque: 13 N.m (130 kgf.cm, 9 ft.lbf) 

      Fig 27: Connecting Floor Shift Gear Shifting Rod Sub-Assy With Nut
      G01028879Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  46. INSTALL OIL COOLER OUTLET TUBE NO.1 
    1. Temporarily install the oil cooler outlet tube No. 1.
    2. Temporarily install the oil cooler inlet tube No. 1.
    3. Install the 2 clamps with the 2 bolts.

      Torque: 5 N.m (51 kgf.cm, 43 in.lbf) 

      Fig 28: Installing Clamps With Bolts
      G01028880Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Tighten the oil cooler outlet tube No. 1.

      Torque: 44 N.m (450 kgf.cm, 32 ft.lbf) 

  47. INSTALL OIL COOLER INLET TUBE NO.1 
    1. Tighten the oil cooler outlet tube No. 1.

      Torque: 44 N.m (450 kgf.cm, 32 ft.lbf) 

  48. INSTALL EXHAUST PIPE NO. 1 SUPPORT BRACKET SUB-ASSY 
    1. Install the exhaust pipe No. 1. support bracket sub-assy with the 2 bolts.

      Torque: 44 N.m (450 kgf.cm, 32 ft.lbf) 

      Fig 29: Installing Exhaust Pipe No. 1. Support Bracket Sub-Assy With 2 Bolts
      G01028881Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  49. CONNECT BATTERY NEGATIVE TERMINAL 
  50. ADJUST SHIFT LEVER POSITION (SEE  ADJUSTMENT  ) 
  51. INSPECT SHIFT LEVER POSITION (SEE  ADJUSTMENT  ) 
  52. INSTALL PROPELLER W/CENTER BEARING SHAFT ASSY (SEE  OVERHAUL  ) 
  53. INSTALL FRONT FLOOR HEAT INSULATOR NO. 1 (SEE  OVERHAUL  ) 
  54. INSTALL EXHAUST PIPE ASSY (SEE  REPLACEMENT  ) 
  55. INSTALL FRONT FLOOR BRACE CENTER (SEE  REPLACEMENT  ) 
  56. ADD AUTOMATIC TRANSMISSION FLUID (SEE  AUTOMATIC TRANSMISSION FLUID  ) 

    Fluid type: ATF WS 

    Capacity: 1.7 liters (1.8 US qts, 1.5 Imp. qts) 

  57. INSTALL ENGINE UNDER COVER NO.2 
  58. INSTALL ENGINE UNDER COVER NO.1 
  59. RESET MEMORY (SEE  INITIALIZATION  ) 
  60. PERFORM INITIALIZATION (SEE  INITIALIZATION  ) 
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