Automatic Transmission Assembly: Installation

1. Inspect the torque converter clutch assembly (see INSPECTION  ).

1. Install the torque converter clutch to the automatic transmission.
2. Using a vernier caliper and straightedge, measure the dimension A between the transmission and the end surface of the drive plate.

   Standard dimension: A = 22.28 mm (0.8772 in.) 

   Fig 1: Measuring Dimension Between Transmission And End Surface Of Drive Plate

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Using a vernier caliper and a straightedge, measure the distance from the installed surface of the transmission housing to the installed surface of the torque converter clutch.

   Correct distance: More than 17.1 mm (0.673 in.) 

Fig 2: Measuring Distance From Installed Surface Of Transmission Housing

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Install the transfer assembly (INSTALLATION ).

1. Connect the 5 hoses and install the wire harness and hose.
2. Install the 6 connector clamps.
3. Connect the 5 connectors.
4. Attach the lock and connect the connector.
5. Install the 4 bolts.

   Torque: 8.0 N*m (82 kgf*cm, 71 in.*lbf) 

Fig 3: Identifying Wire Harness And Hose

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Install the transmission unit with the 10 bolts.

   Torque: 71 N*m (724 kgf*cm, 52 ft.*lbf) for bolt A 

   37 N*m (377 kgf*cm, 27 ft.*lbf) for bolt B 

2. Install the transmission wire clamp bolt.

Fig 4: Identifying Transmission Wire Clamp Bolt

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Install the mounting insulator with the 4 bolts.

   Torque: 59 N*m (600 kgf*cm, 43 ft.*lbf) 

   HINT:

   Install the insulator rear with the inscribing mark facing backward.

Fig 5: Identifying Mounting Insulator With Bolts

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Install the crossmember with the 8 bolts and 2 nuts.

   Torque: 50 N*m (510 kgf*cm, 37 ft.*lbf) for bolt 

   74 N*m (750 kgf*cm, 54 ft.*lbf) for nut 

2. Install the transfer case protector with the 3 bolts.

Torque: 29 N*m (296 kgf*cm, 21 ft.*lbf) 

Fig 6: Identifying Transfer Case Protector With Bolts

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Install the ground cable with the bolt.

Fig 7: Identifying Ground Cable With Bolt

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Loosely install the tip of the oil cooler tubes to the automatic transmission by hand.
2. Install the clamp with the bolt.

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

3. Using SST, tighten the tubes.

   SST 09023-12701 

   Torque: 34 N*m (346 kgf*cm, 25 ft.*lbf) for use 

   without SST 

   31 N*m (316 kgf*cm, 23 ft.*lbf) for use 

   with SST 

Fig 8: Tightening Tubes

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Hold the crankshaft pulley bolt with a wrench and install the 6 torque converter clutch setting bolts.

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

   HINT:

   First install the green colored bolt.

   Fig 9: Identifying Green Colored Bolt

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Install the hole plug with the bolt.

   Torque: 18 N*m (185 kgf*cm, 13 ft.*lbf) 

   Fig 10: Identifying Hole Plug With Bolt

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Connect the transmission wire and install the 3 clamps to the transmission unit.
2. Connect the 3 connectors.

Fig 11: Identifying Transmission Wire

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Connect the shift control rod and install the pin and clip.

Fig 12: Identifying Shift Control Rod

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Connect the transfer shift lever rod assembly with the nut.

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

1. Install the front exhaust pipe RH (INSTALLATION ).

1. Install the transfer shift lever boot with the 4 bolts.

   Torque: 5.4 N*m (55 kgf*cm, 48 in.*lbf) 

2. Install the upper console panel (INSTALLATION ).
3. Install the transfer shift lever knob.

Fig 14: Identifying Transfer Shift Lever Boot With Bolts

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Install the drive belt, fan and fluid coupling assembly, fan shroud and radiator reservoir (INSTALLATION ).

1. Perform initialization (INITIALIZATION ).
   NOTE: Certain systems need to be initialized after disconnecting and reconnecting the cable from the negative (-) battery terminal.

1. Inspect AUTOMATIC TRANSMISSION FLUID  .

Torque: 28 N*m (286 kgf*cm, 21 ft.*lbf) 

1. Install the No. 1 and No. 2 under covers.