Automatic Transaxle Replacement

REMOVAL





1. DISCONNECT THROTTLE CABLE
a) Loosen the 2 nuts and disconnect the throttle cable.
b) Disconnect the throttle cable from cable clamps in the engine compartment.
2. REMOVE ATF LEVEL GAUGE





3. 3RZ-FE:
REMOVE OIL FILLER PIPE UPPER SIDE BOLT
Torque: 12 Nm (120 kgf-cm, 9 ft. lbs.)





4. 5VZ-FE:
REMOVE OIL FILLER PIPE
Remove the bolt and oil filler pipe with O-ring.
Torque: 12 Nm (120 kgf-cm, 9 ft. lbs.)

HINT:
- At the time of installation, please refer to the item.
- Replace the used O-ring with a new one.

5. REMOVE TRANSMISSION SHIFT LEVER ASSEMBLY AND TRANSFER SHIFT LEVER





a) w/o 2-4 selector:
Remove the transfer shift lever knob.
b) w/ 2-4 selector:
Remove the screw and disconnect the transfer shift lever knob.
c) Remove the front console upper panel.
d) w/ 2-4 selector:
Disconnect the 2-4 selector connector and remove the transfer shift lever knob.
e) Remove the 2 clips, screws and front console box.





f) Remove the nut and washer and disconnect the shift control rod.
Torque: 13 Nm (130 kgf-cm, 9 ft. lbs.)





g) Disconnect the connector and remove the 8 bolts and transmission shift lever assembly.
Torque: 5.9 Nm (60 kgf-cm, 52 inch lbs.)





h) Using pliers, remove the snap ring and pull out the transfer shift lever from the transfer.

HINT:
- At the time of installation, please refer to the item.
- Apply MP grease to the transfer shift lever.

6. REMOVE 2 ENGINE UNDER COVERS
7. REMOVE FRONT AND REAR PROPELLER SHAFT
8. REMOVE FRONT EXHAUST PIPE





9. 3RZ-FE:
REMOVE OIL FILLER PIPE
Remove the bolt and oil filler pipe with O-ring.
Torque: 12 Nm (120 kgf-cm, 9 ft. lbs.)

HINT:
- At the time of installation, please refer to the item.
- Replace the used O-ring with a new one.

10. DISCONNECT NO. 2 VEHICLE SPEED SENSOR CONNECTOR FROM TRANSMISSION
11. DISCONNECT SOLENOID CONNECTOR FROM TRANSMISSION
12. DISCONNECT ATF TEMPERATURE SENSOR CONNECTOR FROM TRANSMISSION
13. DISCONNECT PARK/NEUTRAL POSITION SWITCH CONNECTOR FROM TRANSMISSION
14. 3RZ-FE:
DISCONNECT NO.1 VEHICLE SPEED SENSOR CONNECTOR FROM TRANSFER
15. DISCONNECT TRANSFER NEUTRAL POSITION SWITCH CONNECTOR FROM TRANSFER
16. DISCONNECT TRANSFER L4 POSITION SWITCH CONNECTOR FROM TRANSFER
17. DISCONNECT TRANSFER 4WD POSITION SWITCH CONNECTOR FROM TRANSFER
18. w/ 2-4 SELECTOR:
DISCONNECT ACTUATOR CONNECTOR FROM TRANSFER
19. SEPARATE WIRE HARNESS FROM TRANSMISSION AND TRANSFER
20. DISCONNECT OIL COOLER PIPE








a) Remove the 3 bolts and oil cooler pipe clamps.
Torque:
10 mm head bolt:5.0 Nm (51 kgf-cm, 44 ft. lbs.)
12 mm head bolt: 12 Nm (120 kgf-cm, 9 ft. lbs.)





b) Disconnect the 2 oil cooler pipes.
Torque: 34 Nm (350 kgf-cm, 25 ft. lbs.)
21. REMOVE REAR END PLATE AND TORQUE CONVERTER CLUTCH MOUNTING BOLT





a) 3RZ-FE:
Remove the 2 nuts, 4 bolts and rear end plate.
Torque: 18 Nm (185 kgf-cm, 13 ft. lbs.)





b) 5VZ-FE:
Remove the 4 bolts and rear end plate.
Torque: 18 Nm (185 kgf-cm, 13 ft. lbs.)
c) Turn the crankshaft to gain access and remove the 6 bolts with holding the crankshaft pulley set bolt by a wrench.
Torque: 41 Nm (420 kgf-cm, 30 ft. lbs.)

HINT:
- At the time of installation, please refer to the item.
- First install green colored bolt and then 5 other bolts.





22. REMOVE NO. 3 CROSSMEMBER
a) Support the transmission rear side with a support stand.
b) Remove the 4 set bolts of the engine rear mounting.
Torque: 18 Nm (185 kgf-cm, 13 ft. lbs.)
c) Remove the 4 bolts, nuts and No. 3 crossmember.
Torque: 65 Nm (660 kgf-cm, 48 ft. lbs.)
23. REMOVE ENGINE REAR MOUNTING
Remove the 4 bolts and engine rear mounting from the trans-mission.





24. 5VZ-FE (VF3AM type transfer):
REMOVE NO. 4 CROSSMEMBER
Remove the 4 bolts, nuts and No. 4 crossmember.
Torque: 65 Nm (660 kgf-cm, 48 ft. lbs.)





25. JACK UP TRANSMISSION
a) Support the transmission with a transmission jack.
b) Remove a support stand from the transmission rear side.
26. REMOVE STARTER
a) Remove the nut and disconnect the starter wire and connector.
b) Remove the 2 bolts and starter.
Torque: 39 Nm (400 kgf-cm, 29 ft. lbs.)
27. REMOVE TRANSMISSION





a) 3RZ-FE:
Remove the 3 bolts and transmission.
Torque: 71 Nm (730 kgf-cm, 53 ft. lbs.)





b) 5VZ-FE:
Disconnect the stabilizer bar.
c) 5VZ-FE:
Remove the 6 bolts and transmission.
Torque: 71 Nm (730 kgf-cm, 53 ft. lbs.)

INSTALLATION





1. CHECK TORQUE CONVERTER CLUTCH INSTALLATION
Using calipers and a straight edge, measure the distance from the installed surface of the transmission housing to the installed surface of the torque converter clutch.
Correct distance:
3RZ-FE: More than 31.75 mm (1.2500 inch)
5VZ-FE: More than 17.95 mm (0.7067 inch)
2. INSTALL TRANSMISSION
Installation is in the reverse order of removal.

HINT:
- After installation, adjust the shift lever position and throttle cable.
- Fill and check fluid level.