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Automatic Transaxle Assembly: Installation

  1. INSTALL TORQUE CONVERTER CLUTCH ASSEMBLY 
    1. Install the torque converter clutch to the automatic transaxle.
    2. Using vernier calipers and a straight edge, measure dimension "A" between the transaxle fitting part of the engine and the converter fitting part of the drive plate (#).
      Fig 1: Measuring Dimension "A" Between Transaxle Fitting Part Of Engine & Converter Fitting Part Of Drive Plate
      G05415740Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Aligning the matchmarks on the transaxle case and torque converter clutch assembly, engage the splines of the input shaft and turbine runner.
      NOTE: Do not push on the torque converter when aligning the matchmarks.
      Fig 2: Aligning Matchmarks On Transaxle Case & Torque Converter Clutch Assembly
      G05416441Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Engage the splines of the stator shaft and the stator while turning the torque converter clutch assembly.

      HINT:

      Turn the torque converter clutch assembly approximately 180°.

      Fig 3: Engaging Splines Of Stator Shaft & Stator While Turning Torque Converter Clutch Assembly
      G05416442Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Turn the torque converter clutch assembly and align the matchmarks on the torque converter clutch assembly and transaxle case to engage the key of the oil pump drive gear into the slot on the torque converter clutch assembly.
      Fig 4: Aligning Matchmarks On Torque Converter Clutch Assembly & Transaxle Case
      G05416443Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    6. Using vernier calipers and a straight edge, measure dimension "B" shown below and check that "B" is greater than "A" (measured in step (#)).

      Standard: A + 1 mm (0.04 in.) or more 

      NOTE: Make sure to deduct the thickness of the straight edge.
      Fig 5: Measuring Dimension "B" Using Vernier Calipers & Straight Edge
      G05271946Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  2. INSTALL TRANSFER ASSEMBLY  (See REASSEMBLY )
  3. INSTALL AUTOMATIC TRANSAXLE WITH TRANSFER 
    1. Install the automatic transaxle with transfer to the engine with the 10 bolts.

      Torque: Bolt A 

      64 N*m (650 kgf*cm, 47 ft.*lbf) 

      Bolt B 

      46 N*m (470 kgf*cm, 34 ft.*lbf) 

      Bolt C 

      43 N*m (438 kgf*cm, 32 ft.*lbf) 

      Fig 6: Identifying Automatic Transaxle With Transfer & Bolts
      G05137142Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Apply a few drops of adhesive to each of 2 threads on the tip of the 6 torque converter clutch mounting bolts.

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

    3. Install the 6 torque converter clutch mounting bolts.

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

      NOTE: First install the different colored bolt, and then the remaining 5 bolts.
      Fig 7: Identifying Torque Converter Clutch Mounting Bolts
      G05000656Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Install the flywheel housing under cover to the automatic transaxle with the 2 bolts.

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

      Fig 8: Identifying Flywheel Housing Under Cover Bolts
      G05246734Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  4. INSTALL TRANSFER STIFFENER PLATE RH 
    1. Install the transfer stiffener plate RH with 4 bolts to the transfer and engine mounting bracket RR.

      Torque: Bolt A 

      34 N*m (350 kgf*cm, 25 ft.*lbf) 

      Bolt B 

      78 N*m (796 kgf*cm, 58 ft.*lbf) 

      Fig 9: Identifying Transfer Stiffener Plate RH Bolts
      G05416448Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  5. INSTALL TRANSMISSION OIL FILLER TUBE SUB-ASSEMBLY 
    1. Coat a new O-ring with ATF, and install it to the transmission oil filler tube sub-assembly.
    2. Install the transmission oil filler tube sub-assembly to the automatic transaxle with the bolt.

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

      Fig 10: Identifying Transmission Oil Filter Tube Sub-Assembly Bolt
      G05268811Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  6. INSTALL NO. 1 OIL COOLER INLET TUBE 
    1. Temporarily install the No. 1 oil cooler outlet tube.
    2. Temporarily install the No. 1 oil cooler inlet tube.
    3. Install the oil cooler tube clamp with the bolt.

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

      HINT:

      Install them so that the oil cooler tube cushion is positioned as shown below.

      Fig 11: Identifying Oil Cooler Tube Clamp Bolt
      G05268810Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Using union nut wrench (17 mm), install the No. 1 oil cooler inlet tube while holding the union with a wrench.

      Torque: Without union nut wrench 

      34 N*m (347 kgf*cm, 25 ft.*lbf) 

      With union nut wrench 

      32 N*m (326 kgf*cm, 24 ft.*lbf) 

      NOTE:
      • Use a torque wrench with a fulcrum length of 380 mm (14.96 in.).
      • This torque value is effective when union nut wrench is parallel to a torque wrench.
      Fig 12: Identifying Torque Wrench & Fulcrum Length (1 Of 2)
      G05415750Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  7. INSTALL NO. 1 OIL COOLER OUTLET TUBE 
    1. Using union nut wrench, install the No. 1 oil cooler outlet tube while holding the union with a wrench.

      Torque: Without union nut wrench 

      34 N*m (347 kgf*cm, 25 ft.*lbf) 

      With union nut wrench 

      32 N*m (326 kgf*cm, 24 ft.*lbf) 

      NOTE:
      • Use a torque wrench with a fulcrum length of 380 mm (14.96 in.).
      • This torque value is effective when union nut wrench is parallel to a torque wrench.
      Fig 13: Identifying Torque Wrench & Fulcrum Length (2 Of 2)
      G05415751Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  8. INSTALL NO. 1 TRANSMISSION CONTROL CABLE BRACKET 
    1. Install the No. 1 transmission control cable bracket with the 2 bolts.

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

      Fig 14: Identifying No. 1 Transmission Control Cable Bracket Bolts
      G05268807Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  9. CONNECT BREATHER PLUG HOSE 
    1. Connect the breather plug hose to the oil filler tube.
      Fig 15: Identifying Breather Plug Hose & Oil Filler Tube
      G05268805Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  10. CONNECT CONNECTORS 
    1. Connect the transmission wire connector.
    2. Connect the park/neutral position switch connector.
    3. Connect the 2 speed sensor connectors.
      4. Fig 16: Identifying Connectors
      G05415730Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  11. CONNECT WIRE HARNESS 
    1. Connect the wire harness with the bolt.

      Torque: 13 N*m (133 kgf*cm, 10 ft.*lbf) 

      Fig 17: Identifying Wire Harness Bolt
      G05415728Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  12. INSTALL WIRE HARNESS CLAMP 
    1. Install the 3 clamps and 3 bolts.

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

    2. Connect the wire harness with the bolt.

      Torque: 13 N*m (133 kgf*cm, 10 ft.*lbf) 

      3. Fig 18: Identifying Wire Harness Bolts & Clamps
      G05415727Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  13. INSTALL NO. 2 TRANSMISSION CONTROL CABLE BRACKET 
    1. Install the No. 2 transmission control cable bracket with the bolt.

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

      Fig 19: Identifying No. 2 Transmission Control Cable Bracket Bolt
      G05246724Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  14. INSTALL FRONT DRIVE SHAFT ASSEMBLY LH  (See INSTALLATION )
  15. INSTALL FRONT DRIVE SHAFT ASSEMBLY RH (for 4WD)  (See INSTALLATION )
  16. INSTALL TRANSVERSE ENGINE MOUNTING BRACKET  (See INSTALLATION )
  17. INSTALL FRONT ENGINE MOUNTING INSULATOR ASSEMBLY  (See INSTALLATION )
  18. INSTALL TRANSVERSE ENGINE MOUNTING INSULATOR  (See INSTALLATION )
  19. INSTALL TRANSVERSE ENGINE MOUNTING INSULATOR  (See INSTALLATION )
  20. INSTALL FRONT FRAME ASSEMBLY  (See INSTALLATION )
  21. INSTALL POWER STEERING LINK ASSEMBLY (for 4WD)  (See INSTALLATION )
  22. INSTALL FRONT STABILIZER BAR  (See INSTALLATION )
  23. REMOVE ENGINE HANGERS  (See INSTALLATION )
  24. INSTALL MANIFOLD STAY  (See INSTALLATION )
  25. INSTALL STARTER ASSEMBLY  (See INSTALLATION )
  26. INSTALL ENGINE WIRE  (See INSTALLATION )
  27. INSTALL INTAKE AIR SURGE TANK ASSEMBLY  (See INSTALLATION )
  28. INSTALL VENTILATION HOSE  (See INSTALLATION )
  29. TEMPORARILY TIGHTEN COMPRESSOR AND MAGNETIC CLUTCH  (See INSTALLATION )
  30. INSTALL COMPRESSOR AND MAGNETIC CLUTCH  (See INSTALLATION )
  31. INSTALL ENGINE ASSEMBLY WITH TRANSAXLE  (See INSTALLATION )
  32. CONNECT SUCTION HOSE SUB-ASSEMBLY  (See INSTALLATION )
  33. CONNECT DISCHARGE HOSE SUB-ASSEMBLY  (See INSTALLATION )
  34. INSTALL STEERING INTERMEDIATE SHAFT SUB-ASSEMBLY  (See INSTALLATION )
  35. INSTALL FRONT AXLE ASSEMBLY LH  (See INSTALLATION )
  36. INSTALL FRONT AXLE ASSEMBLY RH  (See INSTALLATION )
  37. INSTALL NO. 1 FRONT SUSPENSION LOWER ARM LH  (See INSTALLATION )
  38. INSTALL NO. 1 FRONT SUSPENSION LOWER ARM RH  (See INSTALLATION )
  39. CONNECT TIE ROD ASSEMBLY LH  (See INSTALLATION )
  40. CONNECT TIE ROD ASSEMBLY RH  (See INSTALLATION )
  41. INSTALL FRONT SPEED SENSOR LH  (See INSTALLATION )
  42. INSTALL FRONT SPEED SENSOR RH  (See INSTALLATION )
  43. INSTALL FRONT AXLE HUB NUT LH  (See INSTALLATION )
  44. INSTALL FRONT AXLE HUB NUT RH  (See INSTALLATION )
  45. INSTALL FRONT STABILIZER LINK ASSEMBLY LH  (See INSTALLATION )
  46. INSTALL FRONT STABILIZER LINK ASSEMBLY RH  (See INSTALLATION )
  47. INSTALL FRONT EXHAUST PIPE ASSEMBLY  (See INSTALLATION )
  48. INSTALL FRONT NO. 3 EXHAUST PIPE SUB-ASSEMBLY  (See INSTALLATION )
  49. INSTALL CENTER EXHAUST PIPE ASSEMBLY  (See INSTALLATION )
  50. INSTALL TAIL EXHAUST PIPE ASSEMBLY  (See INSTALLATION )
  51. TEMPORARILY TIGHTEN PROPELLER WITH CENTER BEARING SHAFT ASSEMBLY  (See INSTALLATION )
  52. FULLY TIGHTEN PROPELLER WITH CENTER BEARING SHAFT ASSEMBLY  (See INSTALLATION )
  53. CONNECT ENGINE WIRE  (See INSTALLATION )
  54. CONNECT TRANSMISSION CONTROL CABLE ASSEMBLY  (See INSTALLATION )
  55. CONNECT FUEL TUBE SUB-ASSEMBLY  (See INSTALLATION )
  56. CONNECT OIL COOLER OUTLET HOSE  (See INSTALLATION )
  57. CONNECT OIL COOLER INLET HOSE  (See INSTALLATION )
  58. CONNECT HEATER WATER INLET HOSE B  (See INSTALLATION )
  59. CONNECT HEATER WATER OUTLET HOSE B  (See INSTALLATION )
  60. INSTALL NO. 1 RADIATOR HOSE  (See INSTALLATION )
  61. INSTALL NO. 2 RADIATOR HOSE  (See INSTALLATION )
  62. CONNECT UNION TO CHECK VALVE HOSE  (See INSTALLATION )
  63. CONNECT NO. 1 FUEL VAPOR FEED HOSE  (See INSTALLATION )
  64. INSTALL ENGINE MOVING CONTROL ROD  (See INSTALLATION )
  65. INSTALL NO. 2 ENGINE MOUNTING STAY RH  (See INSTALLATION )
  66. INSTALL RESERVOIR BRACKET  (See INSTALLATION )
  67. INSTALL BRAKE MASTER CYLINDER RESERVOIR ASSEMBLY  (See INSTALLATION )
  68. INSTALL AIR CLEANER BRACKET  (See INSTALLATION )
  69. INSTALL BATTERY  (See INSTALLATION )
  70. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL 
    CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag and seat belt pretensioner activation.
    NOTE: When disconnecting the cable, some systems need to be initialized after the cable is reconnected (See INITIALIZATION ).
  71. INSTALL AIR CLEANER CASE SUB-ASSEMBLY  (See INSTALLATION )
  72. INSTALL AIR CLEANER FILTER ELEMENT SUB-ASSEMBLY  (See INSTALLATION )
  73. INSTALL AIR CLEANER CAP SUB-ASSEMBLY  (See INSTALLATION )
  74. INSTALL NO. 1 AIR CLEANER INLET  (See INSTALLATION )
  75. INSTALL NO. 2 AIR CLEANER INLET  (See INSTALLATION )
  76. CONNECT VACUUM HOSES  (See INSTALLATION )
  77. INSTALL V-RIBBED BELT  (See INSTALLATION )
  78. INSTALL OUTER COWL TOP PANEL SUB-ASSEMBLY  (See INSTALLATION )
  79. INSTALL WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY  (See INSTALLATION )
  80. INSTALL COWL TOP VENTILATOR LOUVER SUB-ASSEMBLY  (See INSTALLATION )
  81. INSTALL FRONT WIPER ARM AND BLADE ASSEMBLY RH  (See INSTALLATION )
  82. INSTALL FRONT WIPER ARM AND BLADE ASSEMBLY LH  (See INSTALLATION )
  83. INSTALL FRONT WHEELS  (See INSTALLATION )
  84. ADD ENGINE OIL  (See REPLACEMENT )
  85. ADD ENGINE COOLANT  (See REPLACEMENT )
  86. INSTALL TRANSFER DRAIN PLUG  (See INSTALLATION )
  87. INSTALL NO. 2 TRANSFER CASE PLUG  (See INSTALLATION )
  88. INSTALL NO. 1 TRANSFER CASE PLUG  (See INSTALLATION )
  89. ADD AUTOMATIC TRANSAXLE FLUID 
  90. CHECK AUTOMATIC TRANSAXLE FLUID  (See REMOVAL  )
  91. INSPECT FOR FUEL LEAK  (See ON-VEHICLE INSPECTION )
  92. INSPECT FOR ENGINE OIL LEAK  (See REPLACEMENT )
  93. INSPECT FOR COOLANT LEAK  (See ON-VEHICLE INSPECTION )
  94. INSPECT FOR EXHAUST GAS LEAK  (See INSTALLATION )
  95. CHECK SHIFT LEVER POSITION  (See ON-VEHICLE INSPECTION  )
  96. CHECK AND ADJUST FRONT WHEEL ALIGNMENT  (See INSTALLATION )
  97. CHECK IGNITION TIMING  (See ON-VEHICLE INSPECTION )
  98. CHECK ENGINE IDLE SPEED  (See ON-VEHICLE INSPECTION )
  99. CHECK CO/HC  (See ON-VEHICLE INSPECTION )
  100. CHECK FUNCTION OF THROTTLE BODY ASSEMBLY  (See ON-VEHICLE INSPECTION )
  101. INSTALL FRONT FENDER APRON SEAL LH  (See INSTALLATION )
  102. INSTALL FRONT FENDER APRON SEAL RH  (See INSTALLATION )
  103. INSTALL FRONT FENDER LINER LH  (See INSTALLATION )
  104. INSTALL FRONT FENDER LINER RH  (See INSTALLATION )
  105. INSTALL FRONT FENDER MOLDING SUB-ASSEMBLY LH  (See INSTALLATION )
  106. INSTALL FRONT FENDER MOLDING SUB-ASSEMBLY RH  (See INSTALLATION )
  107. INSTALL FLOOR UNDER COVER LH 
  108. INSTALL NO. 2 ENGINE UNDER COVER  (See INSTALLATION )
  109. INSTALL NO. 1 ENGINE UNDER COVER  (See INSTALLATION )
  110. INSTALL ENGINE UNDER COVER ASSEMBLY  (See INSTALLATION )
  111. INSTALL V-BANK COVER SUB-ASSEMBLY  (See INSTALLATION )
  112. CHECK ABS SPEED SENSOR SIGNAL  (See INSTALLATION )
  113. RESET MEMORY  (See INSTALLATION )
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