Transmission Installation

The content of this article/image reflects the changes identified in TSB SB0144-10




1. Install the torque converter clutch assembly.





A. Engage the splines of the input shaft and turbine runner.





B. Engage the splines of the stator shaft and the stator while turning the torque converter clutch assembly.

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.





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





D. Using a vernier caliper and a straightedge measure dimension "A" between the transaxle contact surfaces of the engine and the converter contact surfaces of the drive plate.

Make sure to deduct the thickness of the straightedge.





E. Using a vernier caliper and a straightedge measure dimension "B" shown in the illustration and check that "B" is greater than "A" which was measured in the previous step.

Standard: A + 1 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.

2. Install the oil cooler hoses.





A. Install the oil cooler inlet hose.

B. Install the oil cooler outlet hose.





3. Install the No. 1 transmission control cable bracket with the 2 bolts.

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





4. Install the 4 wire harness clamp brackets and 4 bolts.

Torque: 8.4 N*m (86 kgf*cm, 74 in*lbf)





5. Install the speedometer driven hole cover sub-assembly.

A. Coat a new 0-ring with ATF and install it to the hole cover.

B. Install the hole cover to the transaxle case with the bolt.

Torque: 5.5 N*m (56 kgf*cm, 49 in*lbf)





6. Install the Transmission Control Module (TCM) to the transaxle and tighten the 2 bolts in the order shown in the illustration.

Torque: 11 N*m (112 kgf*cm, 9 ft*lbf)





7. Install the engine mounting front bracket to the automatic transaxle with the 3 bolts.

Torque: 64 N*m (653 kgf*cm, 47 ft*lbf)





8. Install the automatic transaxle assembly.

A. Apply clutch spline grease to the contact surface between the crankshaft and torque converter centerpiece.

Clutch spline grease:
Toyota Genuine Clutch Spline Grease, or equivalent

Maximum Amount:
1 g (0.0353 oz.)





B. Keeping the engine and automatic transaxle assembly in a horizontal position align the knock pins with each hole on the automatic transaxle assembly and tighten the 6 bolts shown in the illustration.

Bolt A:

Torque: 64 N*m (653 kgf*cm, 47 ft*lbf)

Bolt B:

Torque: 46 N*m (469 kgf*cm, 34 ft*lbf)

Bolt C:

Torque: 43 N*m (439 kgf*cm, 32 ft*lbf)

NOTICE

^ Confirm that the 2 knock pins are on the transaxle contact surface of the engine block before transaxle installation.

^ Do NOT forcibly pry on the automatic transaxle assembly.

^ Check that the torque converter rotates.

9. Lower transmission jack away from engine and transmission.

10. Install the drive plate and torque converter clutch setting bolt.





A. Apply a few drops of adhesive to 2 threads on the tip of the 6 torque converter clutch mounting bolts.

Adhesive: Toyota Genuine Adhesive 1324, Three Bond 1324, or equivalent





B. Install the 6 torque converter clutch mounting bolts.

Torque: 41 N*m (418 kgf*cm, 30 ft*lbf)

NOTICE

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





11. Install the flywheel housing under cover and exhaust pipe support bracket to the automatic transaxle with the 2 bolts.

Torque: 7.8 N*m (80 kgf*cm, 69 in*lbf)





12. Install the engine mounting insulators with the 3 nuts.

Torque: 87 N*m (887 kgf*cm, 64 ft*lbf)





13. Install the 5 hole plugs.

14. Remove the secondary safety support straps.





15. Install the power steering link assembly with the 2 bolts and 2 nuts.

Torque: 70 N*m (714 kgf*cm, 52 ft*lbf)





16. Install the sub frame using the SST.

SST: 00002-90080

A. Install the frame side rail plates RH and LH with the 4 bolts and 2 nuts.

Nut A:

Torque: 85 N*m (867 kgf*cm, 63 ft*lbf)

Bolt B:

Torque: 32 N*m (329 kgf*cm, 24 ft*lbf)

B. Install the front suspension member brace rear RH and LH with the 4 bolts and 2 nuts.

Nut C:

Torque: 85 N*m (867 kgf*cm, 63 ft*lbf)

Bolt D:

Torque: 32 N*m (329 kgf*cm, 24 ft*lbf)

HINT

SST 00002-90080 will ensure all engine and transmission mount studs have lined up with their corresponding holes.





17. Install the front stabilizer link assembly with the nut.

Torque: 74 N*m (755 kgf*cm, 55 ft*lbf)

18. Install the power steering line back onto the sub frame.





19. Connect the oil cooler hoses.

A. Install the clamp and connect the oil cooler inlet hose.

B. Install the clamp and connect the oil cooler outlet hose.

20. Install the front exhaust pipe assembly back onto the vehicle.

A. Install 2 new gaskets to the exhaust front pipe.





B. Install the exhaust front pipe to the exhaust manifolds with the 4 nuts.

Torque: 62 N*m (632 kgf*cm, 46 ft*lbf)





21. Install the front exhaust pipe No. 1 support brackets with the 2 nuts.

Torque: 33 N*m (337 kgf*cm, 24 ft*lbf)

NOTICE

Be sure to install the support brackets in the correct direction.

22. Reconnect the 02 sensors.





23. Install the front drive shaft assembly LH.

A. Coat the spline of the inboard joint shaft assembly with ATF.

B. Align the shaft splines and install the drive shaft assembly LH with a brass bar and hammer.

NOTICE

^ Set the shaft snap ring with the opening side facing down.

^ Be careful NOT to damage the drive shaft dust cover, boot, or oil seal.

^ Move the drive shaft assembly while keeping it level.





24. Install the front drive shaft assembly RH.

A. Coat the spline of the inboard joint shaft assembly with ATF.

B. Install the front drive shaft assembly RH.

C. Using a screwdriver install a new bearing bracket hole snap ring.

D. Install a new bolt.

Torque: 32 N*m (330 kgf*cm, 24 ft*lbf)

NOTICE

^ Do NOT damage the boot and oil seal.

^ Move the drive shaft assembly while keeping it level.





25. Install the front axle assembly.

Align the matchmarks and install the front drive shaft assembly to the front axle hub sub-assembly.





26. Install the front suspension lower No.1 arm.

Install the lower ball joint to the front suspension lower No.1 arm with the bolt and 2 nuts.

Torque: 75 N*m (765 kgf*cm, 55 ft*lbf)





27. Install the axle hub nuts.

A. Clean the threaded parts on the drive shaft and axle hub nut using a non-residue solvent.

B. Using the SST and applying the brakes install a new front axle hub nut.

SST: 09017-12301 (or equivalent)

Torque: 294 N*m (3,000 kgf*cm, 217 ft*lbf)

C. Using a chisel and hammer stake the front axle hub nut.

28. Remove the Engine Support Bar.





29. Install the upper bell housing bolts.

Torque: 64 N*m (653 kgf*cm, 47 ft*lbf)





30. Connect the transmission control cable assembly.

Install a new clip and the nut and connect the cable to the transaxle.

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

31. Install the starter assembly.





A. Install the starter assembly with the 2 bolts.

Torque: 37 N*m (380 kgf*cm, 28 ft*lbf)

B. Connect the wire harness to terminal 30 and install the nut. Then attach the terminal cap.

Torque: 9.8 N*m (100 kgf*cm, 87 in*lbf)

C. Connect the terminal 50 connector to the starter assembly.

32. Clip in wiring harness to transmission.





A. Connect the park/neutral position switch connector.





B. Connect the wire harness with the bolt.

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





C. Install the 2 bolts and 2 clamps to the body.

Bolt A:

Torque: 12 N*m (123 kgf*cm, 9 ft*lbf)

Bolt B:

Torque: 8.4 N*m (85 kgf*cm, 74 in*lbf)





33. Install the transaxle breather tube.

A. Install the breather bracket to the camshaft housing sub-assembly LH with the bolt.

Torque: 5.5 N*m (56 kgf*cm, 49 in*lbf)

B. Install the breather hose to the breather bracket.

34. Install the intake case and tube assembly.





A. Install the air cleaner case with the 3 bolts.

Torque: 5.0 N*m (51 kgf*cm, 44 in*lbf)





B. Install the No.1 air cleaner inlet with the bolt.

Torque: 5.0 N*m (51 kgf*cm, 44 in*lbf)





C. Install the air cleaner inlet with the clamp and 2 bolts.

Torque: 5.0 N*m (51 kgf*cm, 44 in*lbf)








D. Connect the mass air flow meter connector No. 2 ventilation hose and hose band.

35. Install the plastic covers inside of each fender well.

36. Fill transmission to correct level with transaxle fluid using SST 00002-11100-02.

SST: 00002-11100-02

37. Install the wheels onto the vehicle.

Torque: 103 N*m (1,050 kgf*cm, 76 ft*lbf)





38. Fit the 3 retainers and install the V-bank cover sub-assembly.





39. Install the battery.

A. Install the battery and battery tray.

B. Install the battery clamp with the bolt and nut.

Bolt:

Torque: 9.0 N*m (92 kgf*cm, 80 in*lbf)

Nut:

Torque: 3.5 N*m (36 kgf*cm, 31 in*lbf)





40. Install the engine room side covers.





A. Install the engine room side cover LH with the 6 clips.

B. Install the hood hinge cover LH.





C. Install the engine room side cover RH with the 5 clips.

D. Install the hood hinge cover RH.





41. Install the cool air intake duct seal with the 7 clips.

42. Check for exhaust leaks.

43. Check for fluid leaks.

44. Check shift lever position and operation.

45. Install the engine under covers.

46. Re-initialize auto-power windows and moon roof (if equipped).

47. Test drive vehicle insuring proper operation.

48. Adjust wheel alignment as needed.