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 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
NOTE: 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
NOTE: 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)
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. 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 Testing and Inspection
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 Alignment
73. INSTALL NO. 1 ENGINE COVER SUB-ASSEMBLY Installation
74. CHECK SPEED SENSOR SIGNAL
w/o VSC: Test Mode Procedure
w/ VSC: Test Mode Procedure
75. RESET MEMORY
HINT: Perform RESET MEMORY (AT initialization) when replacing the automatic transaxle assembly Programming and Relearning.