Installation

AA80E AUTOMATIC TRANSMISSION / TRANSAXLE: AUTOMATIC TRANSMISSION ASSEMBLY: INSTALLATION

1. INSTALL TRANSMISSION BREATHER ASSEMBLY

(a) Install the 2 bolts to the transmission breather assembly in the order shown in the illustration.

Bolt 1 - Torque : 7.0 Nm (71 kgf-cm, 62 in-lbf)

Bolt 2 - Torque : 7.0 Nm (71 kgf-cm, 62 in-lbf)

HINT
Be sure to install the transmission breather assembly so that the pipe is positioned between the two-way wire harness.

(b) Connect the 2 wire harness clamps to the transmission breather assembly.

(c) Install the bolt and ground wire to the transmission breather assembly.

Torque : 10 Nm (102 kgf-cm, 7 ft-lbf)

2. INSTALL AUTOMATIC TRANSMISSION BREATHER TUBE

(a) Connect the breather hose to the breather tube.

HINT
Be sure to insert the breather hose to the end.

(b) Install a new O-ring.

(c) Coat the O-ring with ATF.

(d) Install the transmission breather tube with the bolt.

Torque : 5.4 Nm (55 kgf-cm, 48 in-lbf)

3. INSPECT TORQUE CONVERTER CLUTCH ASSEMBLY

(a) Inspect the torque converter clutch Testing and Inspection.

4. INSTALL TORQUE CONVERTER CLUTCH ASSEMBLY

(a) Using a vernier caliper and a straightedge, measure dimension A between the transmission fitting surface of the engine *1 and the converter fitting surface of the drive plate *2. (#)

(b) Aligning the matchmarks on the transmission case and torque converter clutch, engage the splines of the input shaft and turbine runner.

NOTICE:
Do not damage the oil seal.

HINT
Turn the torque converter clutch approximately 180°.

(d) Turn the torque converter clutch and align the matchmarks on the torque converter clutch and transmission case to engage the key of the oil pump drive gear into the slot on the torque converter clutch.

NOTICE:
Do not push on the torque converter when aligning the matchmarks.

(e) Using a vernier caliper and a straightedge, measure dimension B shown in the illustration and check that B is greater than A (measured in step (#)).

Standard:

A + 1 mm (0.04 in.) or more

5. INSTALL AUTOMATIC TRANSMISSION ASSEMBLY

(a) Confirm that 2 knock pins are on the transmission fitting surface of the engine block before transmission installation.

(b) Apply clutch spline grease to the round of the crankshaft contact surface with the torque converter centerpiece.

Clutch spline grease:

Toyota Genuine Clutch Spline Grease or equivalent

Maximum spread:

About 1 g (0.0353 oz.)

(c) Install the automatic transmission to the engine with the 10 bolts.

Bolt A - Torque : 71 Nm (724 kgf-cm, 52 ft-lbf) for 17 mm bolt

Bolt B - Torque : 37 Nm (377 kgf-cm, 27 ft-lbf) for 14 mm bolt

NOTICE:
* Insert dowel pins into the dowel holes securely so that the end face of the automatic transmission assembly fits close against the engine assembly before tightening the bolts.
* Make sure that the dowel pins are not loose, bent, damaged or scratched and then install the transaxle onto the engine with the contact surfaces of the engine and transaxle flat against each other.

6. CONNECT WIRE HARNESS AND CONNECTOR

(a) Install the 2 bolts and wire harness clamp.

Torque : 10 Nm (102 kgf-cm, 7 ft-lbf)

(b) Connect the transmission wire connector.

HINT
Push up the lever until the claw of the transmission wire connector makes a connection sound.

(c) Install the nut and 2 wire harness clamps.

Torque : 10 Nm (102 kgf-cm, 7 ft-lbf)

(d) Connect the park/neutral position switch connector.

7. CONNECT BREATHER PLUG HOSE

(a) Connect the breather hose to the transmission breather assembly.

HINT
Be sure to insert the breather hose until stopped by the protrusion on the transmission breather assembly.

8. INSTALL TRANSMISSION CONTROL SHAFT LEVER RH

(a) Install the transmission control shaft lever with the nut.

Torque : 16 Nm (160 kgf-cm, 12 ft-lbf)

9. INSTALL REAR ENGINE MOUNTING INSULATOR ASSEMBLY

(a) Install the rear engine mounting insulator with the 4 bolts.

Torque : 30 Nm (306 kgf-cm, 22 ft-lbf)

10. INSTALL REAR ENGINE MOUNTING MEMBER

(a) Install the engine rear mounting member to the automatic transmission assembly with the 4 nuts.

Torque : 13 Nm (133 kgf-cm, 10 ft-lbf)

11. INSTALL DRIVE PLATE AND TORQUE CONVERTER CLUTCH SETTING BOLT

(a) Install the 6 torque converter clutch setting bolts while holding the crankshaft pulley bolt with a wrench.

Torque : 48 Nm (490 kgf-cm, 35 ft-lbf)

NOTICE:
Install the black colored bolt first, and then the silver colored 5 bolts.

12. CONNECT OIL COOLER TUBE SUB-ASSEMBLY

(a) Install the oil cooler tube bracket with the 3 bolts.

Torque : 14 Nm (140 kgf-cm, 10 ft-lbf)

(b) Install the 2 oil cooler tubes with the 2 clips.

13. INSTALL NO. 1 EXHAUST PIPE SUPPORT BRACKET SUB-ASSEMBLY

(a) Install the No. 1 exhaust pipe support bracket with the 2 bolts.

Torque : 43 Nm (439 kgf-cm, 32 ft-lbf)

14. INSTALL STARTER ASSEMBLY Installation

15. INSTALL NO. 3 EXHAUST MANIFOLD HEAT INSULATOR Installation

16. INSTALL EXHAUST MANIFOLD SUB-ASSEMBLY RH Installation

17. INSTALL NO. 1 EXHAUST MANIFOLD HEAT INSULATOR Installation

18. INSTALL ENGINE OIL LEVEL DIPSTICK GUIDE Installation

19. INSTALL ENGINE OIL LEVEL DIPSTICK Installation

20. INSTALL ENGINE AND TRANSMISSION

Installation.

21. ADD AUTOMATIC TRANSMISSION FLUID

(a) Add the automatic transmission fluid Procedures.

22. ADJUST SHIFT LEVER POSITION Adjustments

23. INSPECT SHIFT LEVER POSITION Initial Inspection and Diagnostic Overview

24. CHECK AUTOMATIC TRANSMISSION SYSTEM PRECAUTION

(a) After replacing the automatic transmission assembly, certain procedures are necessary Initialization.