Installation

U250E AUTOMATIC TRANSMISSION / TRANSAXLE: AUTOMATIC TRANSAXLE ASSEMBLY: INSTALLATION

1. INSPECT TORQUE CONVERTER CLUTCH ASSEMBLY Testing and Inspection

2. INSTALL TORQUE CONVERTER CLUTCH ASSEMBLY

(a) Using a vernier caliper and a straightedge, measure dimension A between the transaxle contact surface of the engine and the converter contact surface of the drive plate.

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

(d) Align the 2 marks on the transaxle case and torque converter clutch and fit the spline part of the input shaft to the spline part of the turbine runner.

(e) Rotating the torque converter clutch, fit the spline part of the stator shaft to the spline part of the stator.

HINT
Rotate it about 180 degrees.

(f) Rotating the torque converter clutch, align the 2 marks on the case and the torque converter clutch again and fit the key of the oil pump drive gear into the key way of the torque converter clutch.

CAUTION:
Do not apply excessive force to the converter clutch.

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

Standard:

A + 1 mm (0.0394 in.) or more

NOTICE:
Subtract the thickness of the straightedge from the measured value to obtain dimension B.

3. INSTALL WIRE HARNESS CLAMP BRACKET

(a) Install the bracket with the bolt.

Torque : 13 Nm (132 kgf-cm, 10 ft-lbf)

4. INSTALL UPPER TRANSAXLE CASE COVER

(a) Install the upper transmission case cover with the 3 bolts.

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

5. INSTALL SPEEDOMETER DRIVEN HOLE COVER SUB-ASSEMBLY

(a) Coat a new O-ring with ATF WS, and install it to the hole cover.

(b) Install the hole cover to the transaxle case with the bolt.

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

6. INSTALL OIL COOLER TUBE

(a) Connect the 2 oil cooler hoses to the 2 unions with the 2 hose clamps.

(b) Install the oil cooler tube to the automatic transaxle with the bolt.

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

7. INSTALL TRANSMISSION OIL FILLER TUBE SUB-ASSEMBLY

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

(b) Install the oil filler tube to the automatic transaxle with the bolt.

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

(c) Install the transmission oil level gauge sub-assembly.

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. INSTALL ENGINE MOUNTING BRACKET LH

(a) Install the engine mounting bracket LH to the automatic transaxle with the 3 bolts.

Torque : 52 Nm (530 kgf-cm, 38 ft-lbf)

10. INSTALL REAR ENGINE MOUNTING BRACKET

(a) Install the rear engine mounting bracket to the automatic transaxle with the 3 bolts.

Torque : 45 Nm (459 kgf-cm, 33 ft-lbf)

11. INSTALL FRONT ENGINE MOUNTING BRACKET

(a) Install the front engine mounting bracket to the automatic transaxle with the 3 bolts.

Torque : 64 Nm (652 kgf-cm, 47 ft-lbf)

12. INSTALL AUTOMATIC TRANSAXLE ASSEMBLY

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

(a) Install the automatic transaxle to the engine with the 5 bolts.

Bolt A - Torque : 64 Nm (652 kgf-cm, 47 ft-lbf)

Bolt B - Torque : 46 Nm (469 kgf-cm, 34 ft-lbf)

Bolt C - Torque : 46 Nm (469 kgf-cm, 34 ft-lbf)

(b) Install the 4 lower side mounting bolts.

Bolt D - Torque : 44 Nm (448 kgf-cm, 32 ft-lbf)

13. INSTALL ENGINE MOUNTING INSULATOR LH

(a) Install the engine mounting insulator LH with the through bolt and nut.

Torque : 56 Nm (571 kgf-cm, 41 ft-lbf)

14. INSTALL STARTER ASSEMBLY Installation

15. INSTALL DRIVE PLATE AND TORQUE CONVERTER CLUTCH SETTING BOLT

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

Adhesive:

Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent.

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

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

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

(c) Install the flywheel housing under cover.

16. TEMPORARILY TIGHTEN FRONT ENGINE MOUNTING INSULATOR Installation

17. TEMPORARILY TIGHTEN REAR ENGINE MOUNTING INSULATOR Installation

18. TEMPORARILY TIGHTEN CENTER ENGINE MOUNTING MEMBER SUB-ASSEMBLY Installation

19. INSTALL FRONT SUSPENSION CROSSMEMBER SUB-ASSEMBLY Installation

20. FULLY TIGHTEN CENTER ENGINE MOUNTING MEMBER SUB-ASSEMBLY Installation

21. FULLY TIGHTEN FRONT ENGINE MOUNTING INSULATOR Installation

22. FULLY TIGHTEN REAR ENGINE MOUNTING INSULATOR Installation

23. REMOVE ENGINE HANGER

(a) Remove the 2 bolts and 2 engine hangers.

24. INSTALL FRONT DRIVE SHAFT HOLE SNAP RING LH Installation

25. INSTALL FRONT DRIVE SHAFT ASSEMBLY LH Installation

26. INSTALL FRONT DRIVE SHAFT ASSEMBLY RH Installation

27. INSTALL STEERING KNUCKLE WITH AXLE HUB LH Installation

28. INSTALL STEERING KNUCKLE WITH AXLE HUB RH

HINT
Use the same procedure described for the LH side.

29. INSTALL FRONT LOWER SUSPENSION ARM SUB-ASSEMBLY LH Installation

30. INSTALL FRONT LOWER SUSPENSION ARM SUB-ASSEMBLY RH

HINT
Use the same procedure described for the LH side.

31. INSTALL FRONT STABILIZER LINK ASSEMBLY LH Installation

32. INSTALL FRONT STABILIZER LINK ASSEMBLY RH

HINT
Use the same procedure described for the LH side.

33. CONNECT TIE ROD END SUB-ASSEMBLY LH Installation

34. CONNECT TIE ROD END SUB-ASSEMBLY RH

HINT
Use the same procedure described for the LH side.

35. INSTALL FRONT SPEED SENSOR LH Installation

36. INSTALL FRONT SPEED SENSOR RH

HINT
Use the same procedure described for the LH side.

37. INSTALL FRONT AXLE SHAFT NUT LH Installation

38. INSTALL FRONT AXLE SHAFT NUT RH

HINT
Use the same procedure described for the LH side.

39. INSTALL CENTER EXHAUST PIPE ASSEMBLY Installation

40. INSTALL NO. 1 STEERING COLUMN HOLE COVER SUB-ASSEMBLY Installation

41. INSTALL NO. 2 STEERING INTERMEDIATE SHAFT ASSEMBLY Installation

42. CONNECT COLUMN HOLE COVER SILENCER SHEET Installation

43. INSTALL TRANSMISSION CONTROL CABLE ASSEMBLY Installation

44. INSTALL BREATHER HOSE

(a) Install the breather hose.

45. INSTALL WIRE HARNESS AND CONNECTOR

(a) Install the 3 engine wire clamps and speed sensor connector.

(b) Install the transmission control cable support with the bolt.

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

(c) Install the engine wire clamp, speed sensor connector, park/neutral position switch connector and transmission wire connector.

46. INSTALL OIL COOLER HOSE Installation

47. INSTALL WIRE HARNESS Installation

48. INSTALL BATTERY CARRIER Installation

49. INSTALL BATTERY Installation

50. INSTALL AIR CLEANER CASE Installation

51. INSTALL AIR CLEANER CAP SUB-ASSEMBLY Installation

52. TEMPORARILY TIGHTEN HOOD SUB-ASSEMBLY

(a) Install the hood sub-assembly with the 4 bolts.

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

(b) Install the washer hose and 2 washer hose clamps.

53. INSPECT HOOD SUB-ASSEMBLY

54. ADJUST HOOD SUB-ASSEMBLY

Adjustments

55. INSTALL OUTER COWL TOP PANEL Installation

56. INSTALL WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY Installation

57. INSTALL COWL TOP VENTILATOR LOUVER LH Installation

58. INSTALL COWL TOP VENTILATOR LOUVER RH Installation

59. INSTALL HOOD TO COWL TOP SEAL Installation

60. INSTALL FRONT WIPER ARM AND BLADE ASSEMBLY RH Installation

61. INSTALL FRONT WIPER ARM AND BLADE ASSEMBLY LH Installation

62. INSTALL FRONT WIPER ARM HEAD CAP Installation

63. INSTALL FRONT WHEELS Installation

64. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL Installation

65. ADD AUTOMATIC TRANSAXLE FLUID

66. INSPECT TRANSAXLE FLUID LEVEL Procedures

67. INSPECT FOR EXHAUST GAS LEAK

68. INSPECT SHIFT LEVER POSITION Adjustments

69. ADJUST SHIFT LEVER POSITION Adjustments

70. INSTALL ENGINE UNDER COVER LH

71. INSTALL ENGINE UNDER COVER RH

72. INSPECT AND ADJUST FRONT WHEEL ALIGNMENT

Service and Repair

73. INSTALL NO. 1 ENGINE COVER SUB-ASSEMBLY Installation

74. CHECK SPEED SENSOR SIGNAL

Test Mode Procedure

75. RESET MEMORY

HINT
Perform RESET MEMORY (AT initialization) when replacing the automatic transaxle assembly Programming and Relearning.