Installation

U250E AUTOMATIC TRANSMISSION / TRANSAXLE: AUTOMATIC TRANSAXLE ASSEMBLY: INSTALLATION

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 fitting surface of the engine and the converter fitting surface of the drive plate. (#1)

(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 the torque converter clutch about 180°.

(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: When rotating the torque converter clutch, do not rotate it with excessive force.

(g) Using a vernier caliper and a straightedge, measure dimension "B" shown in the illustration and check that "B" is greater than "A" (measured in step (#1)).
Standard:
A + 1 mm (0.0394 in.) or more
NOTE: Remember to subtract the thickness of the straightedge.

3. INSTALL WIRE HARNESS CLAMP BRACKET

(a) Install the bracket with the bolt.
Torque: 11 Nm (112 kgf-cm, 8 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 sub-assembly 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.

(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
NOTE: Make sure the knock pins are fully engaged and the transaxle securely fitted to the engine before tightening the bolts.

(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 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.
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 bolts tip.
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)
NOTE: 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. INSTALL ENGINE ASSEMBLY WITH TRANSAXLE
HINT: See the steps from "Install Engine Assembly with Transaxle" through "Check ABS Speed Sensor Signal" Installation.

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