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Home >> Toyota Truck >> 2012 >> Highlander 4WD V6-3.5L (2GR-FE) >> Repair and Diagnosis >> Transmission and Drivetrain >> Automatic Transmission/Transaxle >> Service and Repair >> Removal and Replacement >> Automatic Transaxle Assembly >> Installation

Installation





U151F AUTOMATIC TRANSAXLE: AUTOMATIC TRANSAXLE ASSEMBLY: INSTALLATION

1. INSTALL TORQUE CONVERTER CLUTCH ASSEMBLY

(a) Install the torque converter clutch to the automatic transaxle.

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





NOTICE:
Subtract the thickness of the straightedge from the measured value to gain dimension A.

(c) Set the key at the top of the front oil pump drive gear and put a mark on the housing.





(d) Put a mark on the torque converter so that its groove is clearly indicated.





(e) Align the matchmark on the case with the one on the torque converter and fit the splines of the input shaft to the turbine runner splines.





(f) After rotating the torque converter, fit the splines of the stator shaft with the stator splines.





HINT
Rotate the torque converter approximately 180 degrees.

(g) After rotating the torque converter again, align the mark on the case with the one on the torque converter and fit the key of the oil pump drive gear into the torque converter keyway.





NOTICE:
Do not push the torque converter excessively when rotating it.

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





Standard:

A + 1 mm (0.04 in.) or more

NOTICE:
Make sure to deduct the thickness of the straightedge.

2. INSTALL TRANSFER ASSEMBLY Installation

3. INSTALL AUTOMATIC TRANSAXLE WITH TRANSFER

(a) Install the automatic transaxle with transfer to the engine with the 10 bolts.





Bolt A - Torque : 64 Nm (650 kgf-cm, 47 ft-lbf)

Bolt B - Torque : 46 Nm (470 kgf-cm, 34 ft-lbf)

Bolt C - Torque : 43 Nm (438 kgf-cm, 32 ft-lbf)

NOTICE:
Confirm that 2 knock pins are on the transaxle fitted surface of the engine block before the transaxle installation.

(b) Apply a few drops of adhesive to the first 2 or 3 threads of the 6 torque converter clutch mounting bolts.





Adhesive:

Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

(c) Install the 6 torque converter clutch mounting bolts.





Torque : 41 Nm (418 kgf-cm, 30 ft-lbf)

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

(d) Install the flywheel housing under cover to the automatic transaxle with the 2 bolts.





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

4. INSTALL TRANSFER STIFFENER PLATE RH

(a) Install the transfer stiffener plate RH with 4 bolts to the transfer and engine mounting bracket RR.





Bolt A - Torque : 34 Nm (350 kgf-cm, 25 ft-lbf)

Bolt B - Torque : 78 Nm (796 kgf-cm, 58 ft-lbf)

5. INSTALL TRANSMISSION OIL FILLER TUBE SUB-ASSEMBLY

(a) Coat a new O-ring with ATF and install it to the transmission oil filler tube sub-assembly.

(b) Install the transmission oil filler tube sub-assembly to the automatic transaxle with the bolt.





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

6. INSTALL NO. 1 OIL COOLER INLET TUBE

(a) Temporarily install the No. 1 oil cooler outlet tube.

(b) Temporarily install the No. 1 oil cooler inlet tube.

(c) Install the oil cooler tube clamp with the bolt.





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

HINT
Install them so that the oil cooler tube cushion is positioned as shown in the illustration.

(d) Using a union nut wrench (17 mm), install the No. 1 oil cooler inlet tube while holding the union with a wrench.

Without a union nut wrench - Torque : 34 Nm (347 kgf-cm, 25 ft-lbf)

With a union nut wrench - Torque : 32 Nm (326 kgf-cm, 24 ft-lbf)

NOTICE:
* Use a torque wrench with a fulcrum length of 380 mm (14.96 in.).
* This torque value is effective when the union nut wrench is parallel to the torque wrench.





7. INSTALL NO. 1 OIL COOLER OUTLET TUBE

(a) Using a union nut wrench, install the No. 1 oil cooler outlet tube while holding the union with a wrench.

Without a union nut wrench - Torque : 34 Nm (347 kgf-cm, 25 ft-lbf)

With a union nut wrench - Torque : 32 Nm (326 kgf-cm, 24 ft-lbf)

NOTICE:
* Use a torque wrench with a fulcrum length of 380 mm (14.96 in.).
* This torque value is effective the when union nut wrench is parallel to the torque wrench.





8. INSTALL NO. 1 TRANSMISSION CONTROL CABLE BRACKET

(a) Install the No. 1 transmission control cable bracket with the 2 bolts.





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

9. CONNECT BREATHER PLUG HOSE

(a) Connect the breather plug hose to the oil filler tube.





10. CONNECT CONNECTORS

(a) Connect the transmission wire connector.





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

(c) Connect the 2 speed sensor connectors.

11. CONNECT WIRE HARNESS

(a) Connect the wire harness with the bolt.





Torque : 20 Nm (204 kgf-cm, 15 ft-lbf)

12. INSTALL WIRE HARNESS CLAMP

(a) Install the 3 clamps and 3 bolts.





Torque : 8.5 Nm (87 kgf-cm, 75 in-lbf)

(b) Connect the wire harness with the bolt.

Torque : 20 Nm (204 kgf-cm, 15 ft-lbf)

13. INSTALL NO. 2 TRANSMISSION CONTROL CABLE BRACKET

(a) Install the No. 2 transmission control cable bracket with the bolt.





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

14. INSTALL FRONT DRIVE SHAFT ASSEMBLY LH Installation

15. INSTALL FRONT DRIVE SHAFT ASSEMBLY RH (for 4WD) Installation

16. INSTALL TRANSVERSE ENGINE MOUNTING BRACKET Installation

17. INSTALL FRONT ENGINE MOUNTING INSULATOR ASSEMBLY Installation

18. INSTALL TRANSVERSE ENGINE MOUNTING INSULATOR Installation

19. INSTALL TRANSVERSE ENGINE MOUNTING INSULATOR Installation

20. INSTALL FRONT FRAME ASSEMBLY Installation

21. INSTALL POWER STEERING LINK ASSEMBLY (for 4WD) Installation

22. INSTALL FRONT STABILIZER BAR Installation

23. REMOVE ENGINE HANGERS Installation

24. INSTALL MANIFOLD STAY Installation

25. INSTALL STARTER ASSEMBLY Installation

26. INSTALL ENGINE WIRE Installation

27. INSTALL INTAKE AIR SURGE TANK ASSEMBLY Installation

28. INSTALL VENTILATION HOSE Installation

29. TEMPORARILY TIGHTEN COMPRESSOR AND MAGNETIC CLUTCH Installation

30. INSTALL COMPRESSOR AND MAGNETIC CLUTCH Installation

31. INSTALL ENGINE ASSEMBLY WITH TRANSAXLE Installation

32. CONNECT SUCTION HOSE SUB-ASSEMBLY Installation

33. CONNECT DISCHARGE HOSE SUB-ASSEMBLY Installation

34. INSTALL STEERING INTERMEDIATE SHAFT SUB-ASSEMBLY Installation

35. INSTALL FRONT AXLE ASSEMBLY LH Installation

36. INSTALL FRONT AXLE ASSEMBLY RH Installation

37. INSTALL NO. 1 FRONT SUSPENSION LOWER ARM LH Installation

38. INSTALL NO. 1 FRONT SUSPENSION LOWER ARM RH Installation

39. CONNECT TIE ROD ASSEMBLY LH Installation

40. CONNECT TIE ROD ASSEMBLY RH Installation

41. INSTALL FRONT SPEED SENSOR LH Installation

42. INSTALL FRONT SPEED SENSOR RH Installation

43. INSTALL FRONT AXLE HUB NUT LH Installation

44. INSTALL FRONT AXLE HUB NUT RH Installation

45. INSTALL FRONT STABILIZER LINK ASSEMBLY LH Installation

46. INSTALL FRONT STABILIZER LINK ASSEMBLY RH Installation

47. INSTALL FRONT EXHAUST PIPE ASSEMBLY Installation

48. INSTALL FRONT NO. 3 EXHAUST PIPE SUB-ASSEMBLY Installation

49. INSTALL CENTER EXHAUST PIPE ASSEMBLY Removal

50. INSTALL TAIL EXHAUST PIPE ASSEMBLY Removal

51. TEMPORARILY TIGHTEN PROPELLER WITH CENTER BEARING SHAFT ASSEMBLY Installation

52. FULLY TIGHTEN PROPELLER WITH CENTER BEARING SHAFT ASSEMBLY Installation

53. CONNECT ENGINE WIRE Installation

54. CONNECT TRANSMISSION CONTROL CABLE ASSEMBLY Installation

55. CONNECT FUEL TUBE SUB-ASSEMBLY Installation

56. CONNECT OIL COOLER OUTLET HOSE Installation

57. CONNECT OIL COOLER INLET HOSE Installation

58. CONNECT HEATER WATER HOSE INLET B Installation

59. CONNECT HEATER WATER HOSE OUTLET B Installation

60. INSTALL NO. 1 RADIATOR HOSE Installation

61. INSTALL NO. 2 RADIATOR HOSE Installation

62. CONNECT UNION TO CHECK VALVE HOSE Installation

63. CONNECT NO. 1 FUEL VAPOR FEED HOSE Installation

64. INSTALL ENGINE MOVING CONTROL ROD Installation

65. INSTALL NO. 2 ENGINE MOUNTING STAY RH Installation

66. INSTALL RESERVOIR BRACKET Installation

67. INSTALL BRAKE MASTER CYLINDER RESERVOIR ASSEMBLY Installation

68. INSTALL AIR CLEANER BRACKET Installation

69. INSTALL BATTERY 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.

NOTICE:
When disconnecting the cable, some systems need to be initialized after the cable is reconnected Repair Instruction - Initialization.

71. INSTALL AIR CLEANER CASE SUB-ASSEMBLY Installation

72. INSTALL AIR CLEANER FILTER ELEMENT SUB-ASSEMBLY Installation

73. INSTALL AIR CLEANER CAP SUB-ASSEMBLY Installation

74. INSTALL NO. 1 AIR CLEANER INLET Installation

75. INSTALL NO. 2 AIR CLEANER INLET Installation

76. CONNECT VACUUM HOSES Installation

77. INSTALL V-RIBBED BELT Installation

78. INSTALL OUTER COWL TOP PANEL SUB-ASSEMBLY Installation

79. INSTALL WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY Installation

80. INSTALL COWL TOP VENTILATOR LOUVER SUB-ASSEMBLY Installation

81. INSTALL FRONT WIPER ARM AND BLADE ASSEMBLY RH Installation

82. INSTALL FRONT WIPER ARM AND BLADE ASSEMBLY LH Installation

83. INSTALL FRONT WHEELS Installation

84. ADD ENGINE OIL Replacement

85. ADD ENGINE COOLANT Service and Repair

86. INSTALL TRANSFER DRAIN PLUG Installation

87. INSTALL NO. 2 TRANSFER CASE PLUG Installation

88. INSTALL NO. 1 TRANSFER CASE PLUG Installation

89. ADD AUTOMATIC TRANSAXLE FLUID

90. CHECK AUTOMATIC TRANSAXLE FLUID Procedures

91. INSPECT FOR FUEL LEAK Fuel System

92. INSPECT FOR ENGINE OIL LEAK Replacement

93. INSPECT FOR COOLANT LEAK Testing and Inspection

94. INSPECT FOR EXHAUST GAS LEAK Installation

95. INSPECT SHIFT LEVER POSITION Initial Inspection and Diagnostic Overview

96. ADJUST SHIFT LEVER POSITION Adjustments

97. CHECK AND ADJUST FRONT WHEEL ALIGNMENT Installation

98. CHECK IGNITION TIMING On-Vehicle Inspection

99. CHECK ENGINE IDLE SPEED On-Vehicle Inspection

100. CHECK CO/HC On-Vehicle Inspection

101. CHECK FUNCTION OF THROTTLE BODY ASSEMBLY On-Vehicle Inspection

102. INSTALL FRONT FENDER APRON SEAL LH Installation

103. INSTALL FRONT FENDER APRON SEAL RH Installation

104. INSTALL FRONT FENDER LINER LH Installation

105. INSTALL FRONT FENDER LINER RH Installation

106. INSTALL FRONT FENDER MOULDING SUB-ASSEMBLY LH Installation

107. INSTALL FRONT FENDER MOULDING SUB-ASSEMBLY RH Installation

108. INSTALL FLOOR UNDER COVER LH

109. INSTALL NO. 2 ENGINE UNDER COVER Installation

110. INSTALL NO. 1 ENGINE UNDER COVER Installation

111. INSTALL ENGINE UNDER COVER ASSEMBLY Installation

112. INSTALL V-BANK COVER SUB-ASSEMBLY Installation

113. CHECK ABS SPEED SENSOR SIGNAL Installation

114. RESET MEMORY Installation
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