AUTOMATIC TRANSMISSION ASSEMBLY > INSTALLATION

for Preparation Click here

1. Inspect the torque converter clutch assembly (Click here ).
   

1. Install the torque converter clutch to the automatic transmission.
   

2. Using a vernier caliper and straightedge, measure dimension A between the transmission and the end surface of the drive plate.
   

   Standard:

   A = 22.28 mm (0.8772 in.)
   

3. Using a vernier caliper and straightedge, measure dimension B shown in the illustration. Check that B is greater than A.
   

   Standard:

   B = A + 1.00 mm (0.0394 in.) or more
   

1. Install the transfer assembly (Click here).
   

1. Install the engine mounting insulator to the transmission with the 4 bolts.
   

   Torque:

   65 N*m{ 663 kgf*cm , 48 ft.*lbf }

1. Install the transmission to the engine with the 5 bolts.
   

   Torque:

   71 N*m{ 720 kgf*cm , 53 ft.*lbf }

2. Hold the crankshaft pulley bolt with a wrench and install the 6 torque converter clutch mounting bolts.
   

   Torque:

   41 N*m{ 421 kgf*cm , 30 ft.*lbf }

1. Install the No. 2 end plate.
   

2. Install the No. 4 cylinder block insulator.
   

3. Install the stiffener plate LH to the engine and transmission with the 4 bolts.
   

   Torque:

   71 N*m{ 720 kgf*cm , 53 ft.*lbf }

4. Install the stiffener plate RH (with clamp tube) to the engine and transmission with the 4 bolts.
   

   Torque:

   71 N*m{ 720 kgf*cm , 53 ft.*lbf }

1. Transmission side:
   Connect the connectors.
   
   

   1. Connect the temperature sensor connector.
      

   2. Connect the park/neutral position switch connector.
      

   3. Connect the 2 speed sensor connectors.
      

   4. Connect the transmission wire connector.
      

2. Transfer side:
   Connect the connectors.
   
   

   1. Connect the indicator switch connector (4WD).
      

   2. Connect the speedometer sensor connector.
      

   3. Connect the indicator switch connector (L4).
      

   4. Connect the indicator switch connector (neutral).
      

1. *2 Install the frame crossmember with the 4 bolts and 4 nuts.
   

   Torque:

   50 N*m{ 510 kgf*cm , 37 ft.*lbf }

2. *1 Install the 4 set bolts of the engine mounting insulator.
   

   Torque:

   27 N*m{ 275 kgf*cm , 20 ft.*lbf }

1. Install the starter assembly (Click here).
   

1. Install the control cable bracket with the 2 bolts.
   

   Torque:

   28 N*m{ 286 kgf*cm , 21 ft.*lbf }

1. Connect the control cable with the clip.
   

2. Connect the control cable with the nut.
   

   Torque:

   14 N*m{ 143 kgf*cm , 10 ft.*lbf }

1. Loosely install the tip of the oil cooler tube inlet to the automatic transmission by hand.
   

2. Loosely install the tip of the oil cooler tube outlet to the automatic transmission by hand.
   

3. Install the 3 clamps with the 3 bolts.
   

   Torque:

   5.0 N*m{ 50 kgf*cm , 43 in.*lbf } for A and B

   12 N*m{ 122 kgf*cm , 9 ft.*lbf } for C

4. Using SST, tighten the inlet and outlet tubes.
   

   SST

   09023-12701  
   

   Torque:

   34 N*m{ 346 kgf*cm , 25 ft.*lbf } for use without SST

   31 N*m{ 316 kgf*cm , 23 ft.*lbf } for use with SST

   HINT:

   Use a torque wrench with a fulcrum length of 30 cm (11.81 in.).

1. Coat a new O-ring with ATF, and install it to the oil filler tube.
   

2. Install the oil filler tube to the transmission with the 2 bolts.
   

   Torque:

   12 N*m{ 122 kgf*cm , 9 ft.*lbf }

3. Install the oil level gauge.
   

1. Install the propeller shaft with center bearing assembly (Click here).
   

1. Install the front propeller shaft assembly (Click here).
   

1. Install the transfer case lower protector with the 4 bolts.
   

   Torque:

   18 N*m{ 183 kgf*cm , 13 ft.*lbf }

1. Using a vernier caliper, measure the free length of the compression spring.
   

   Minimum length:

   40 mm (1.57 in.)
   If the free length is less than the minimum, replace the compression spring.
   

2. Install the front pipe to the pipe support.
   

3. Install a new gasket to the outlet pipe.
   

   NOTICE:

   1. Be careful with the installation direction of the gasket.
      
   1. Do not reuse the gasket.
      
   1. To ensure a proper seal, do not use the front pipe to force the gasket onto the outlet pipe.
      

   HINT:

   1. Using a plastic-faced hammer, uniformly strike the gasket so that the gasket and outlet pipe are properly fit.
      

4. Install the front pipe with the 2 compression springs and 2 bolts. Alternately tighten the bolts in several passes.
   

   Torque:

   43 N*m{ 438 kgf*cm , 32 ft.*lbf }

   CAUTION:

   Do not reuse the gasket.

1. Install the transfer shift lever to the shift lever retainer.
   

2. Using needle-nose pliers, install the snap ring.
   

3. Install the shift lever boot with the 4 bolts.
   

   Torque:

   18 N*m{ 283 kgf*cm , 13 ft.*lbf }

   HINT:

   Apply MP grease to the tip of the transfer shift lever.

1. Install the shift lever boot with the 4 screws.
   

1. Adjust the shift lever position (Click here).
   

1. Add automatic transmission fluid (Click here)
   

   Fluid type:

   Toyota Genuine ATF TYPE T-IV
   

1. Perform initialization (Click here).
   

   NOTICE:

   Certain systems need to be initialized after disconnecting and reconnecting the cable from the negative (-) battery terminal.

1. Inspect the shift lever position (Click here).
   

1. Install the console box assembly (Click here).
   

1. Inspect the automatic transmission fluid (Click here).
   

Torque:

28 N*m{ 285 kgf*cm , 21 ft.*lbf }

Torque:

28 N*m{ 285 kgf*cm , 21 ft.*lbf }