Installation

AB60E AUTOMATIC TRANSMISSION: AUTOMATIC TRANSMISSION ASSEMBLY: INSTALLATION

1. INSTALL TORQUE CONVERTER ASSEMBLY

(a) Using a vernier caliper and 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, and then engage the splines of the input shaft and turbine runner.

HINT
Turn the torque converter approximately 180°.

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

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 the first step.

Standard distance:

B = A + 1 mm (0.0394 in.) or more

2. INSTALL TRANSMISSION CONTROL CABLE BRACKET

(a) Install the bracket with the 2 bolts.

Torque : 12 Nm (122 kgf-cm, 9 ft-lbf)

3. INSTALL WIRE HARNESS CLAMP BRACKET

(a) Install the front bracket LH with the bolt.

Torque : 8.0 Nm (82 kgf-cm, 71 in-lbf)

(b) Install the rear bracket LH with the bolt.

Torque : 29 Nm (296 kgf-cm, 21 ft-lbf)

(c) Install the rear engine bracket with the bolt.

Torque : 8.0 Nm (82 kgf-cm, 71 in-lbf)

4. INSTALL TRANSMISSION OIL COOLER ASSEMBLY (w/o Trailer Towing System)

(a) Coat 4 new O-rings with ATF.

(b) Install the 4 O-rings, transmission oil cooler spacer and transmission oil cooler to the automatic transmission assembly with the 3 bolts.

Torque : 21 Nm (214 kgf-cm, 25 in-lbf)

5. INSTALL TRANSMISSION OIL COOLER ASSEMBLY (w/ Trailer Towing System)

(a) Coat 4 new O-rings with ATF.

(b) Install the 4 O-rings, transmission oil thermostat and transmission oil cooler to the automatic transmission assembly with the 3 bolts.

Torque : 21 Nm (214 kgf-cm, 25 in-lbf)

6. INSTALL AUTOMATIC TRANSMISSION ASSEMBLY

(a) Apply clutch spline grease to the surface of the torque converter centerpiece that contacts the crankshaft.

Clutch spline grease:

Toyota Genuine Clutch Spline Grease or equivalent

Maximum grease amount
Approximately 1 g (0.0353 oz.) Centerpiece

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

(c) Install the transmission with the 10 bolts.

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

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

7. CONNECT NO. 2 WATER BY-PASS PIPE (w/o Trailer Towing System)

(a) Connect the 2 water by-pass hoses with the 2 clips and install the water by-pass pipe with the bolt.

Torque : 18 Nm (184 kgf-cm, 13 ft-lbf)

NOTICE:
Make sure the pinching portion of each clip is facing the direction shown in the illustration.

8. CONNECT NO. 2 WATER BY-PASS PIPE (w/ Trailer Towing System)

(a) Connect the 2 oil cooler hoses to the transmission oil thermostat.

NOTICE:
* Make sure the pinching portion of each clip is facing the direction shown in the illustration.
* Make sure the paint portion of each hose is facing outward.

(b) Connect the 2 water by-pass hoses with the 2 clips and install the water by-pass pipe with the bolt.

Torque : 18 Nm (184 kgf-cm, 13 ft-lbf)

NOTICE:
Pinching portion of clip shall be directed as shown in the illustration.

9. CONNECT BREATHER PLUG HOSE

(a) Connect the breather plug hose to the harness clamp bracket.

10. CONNECT WIRE HARNESS AND CONNECTOR

(a) Connect the park/neutral start switch connector, 2 transmission wire connectors and 2 speed sensor connectors.

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

(b) Connect the harness clamp with the bolt.

Torque : 8.2 Nm (84 kgf-cm, 73 in-lbf)

(c) Connect the 3 connector clamps and 4 harness clamps.

(d) Tilt up the automatic transmission.

(e) Connect the ground cable with the bolt.

Torque : 5.5 Nm (56 kgf-cm, 49 in-lbf)

11. INSTALL REAR NO. 1 ENGINE MOUNTING INSULATOR

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

Torque : 40 Nm (407 kgf-cm, 30 ft-lbf)

12. INSTALL NO. 3 FRAME CROSSMEMBER SUB-ASSEMBLY

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

Torque : 21 Nm (214 kgf-cm, 15 ft-lbf)

(b) Install the frame crossmember with the 4 bolts, 4 washers and 4 nuts.

Torque : 110 Nm (1122 kgf-cm, 81 ft-lbf)

13. INSTALL DRIVE PLATE AND TORQUE CONVERTER CLUTCH SETTING BOLT

(a) Turn the crankshaft to gain access to the 6 bolts and install the bolts while holding the crankshaft pulley set bolt with a wrench.

Torque : 53 Nm (535 kgf-cm, 39 ft-lbf)

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

(b) Install the flywheel housing side cover.

14. INSTALL STARTER ASSEMBLY

Installation

15. CONNECT TRANSMISSION CONTROL CABLE ASSEMBLY

(a) Connect the control cable with a new clip and the nut.

Torque : 14 Nm (143 kgf-cm, 10 ft-lbf)

NOTICE:
When connecting the cable to the transmission control shaft lever, make sure the cable's L bracket faces the outside of the vehicle.

16. INSTALL PROPELLER SHAFT ASSEMBLY

Installation

17. INSTALL FRONT EXHAUST PIPE ASSEMBLY

(a) for Regular Cab Standard Deck:

Installation.

(b) except Regular Cab Standard Deck:

Installation.

18. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

19. ADD AUTOMATIC TRANSMISSION FLUID

Procedures

20. ADD ENGINE COOLANT Service and Repair

21. CHECK FOR ENGINE COOLANT LEAK Testing and Inspection

22. ADJUST SHIFT LEVER POSITION Shift Lever Assembly (for Column Shift Type)

23. INSPECT SHIFT LEVER POSITION Shift Lever Assembly (for Column Shift Type)

24. CHECK FOR EXHAUST GAS LEAK Installation

25. INSTALL NO. 1 ENGINE UNDER COVER

26. RESET MEMORY

Programming and Relearning