GSIC - Global Service Information Center

# AUTOMATIC TRANSMISSION ASSEMBLY > INSTALLATION

## for Preparation Click here

1. INSPECT TORQUE CONVERTER CLUTCH ASSEMBLY

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

2. INSTALL TORQUE CONVERTER CLUTCH ASSEMBLY

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

1. 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.)

1. 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

3. INSTALL TRANSFER ASSEMBLY

1. Install the transfer assembly (Click here).

4. INSTALL NO. 1 ENGINE MOUNTING INSULATOR REAR

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

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

5. INSTALL AUTOMATIC TRANSMISSION ASSEMBLY

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

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

1. 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 }

6. INSTALL STIFFENER PLATE

1. Install the No. 2 end plate.

1. Install the No. 4 cylinder block insulator.

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

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

1. 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 }

7. CONNECT WIRE HARNESS

8. CONNECT CONNECTOR

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.

1. 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).

9. INSTALL NO. 3 FRAME CROSSMEMBER SUB-ASSEMBLY

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

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

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

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

10. INSTALL STARTER ASSEMBLY

1. Install the starter assembly (Click here).

11. INSTALL TRANSMISSION CONTROL CABLE BRACKET

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

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

12. CONNECT TRANSMISSION CONTROL SHIFT CABLE ASSEMBLY

1. Connect the control cable with the clip.

1. Connect the control cable with the nut.

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

13. INSTALL OIL COOLER TUBE

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

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

1. 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

1. 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.).

14. INSTALL TRANSMISSION OIL FILLER TUBE SUB-ASSEMBLY

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

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

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

1. Install the oil level gauge.

15. INSTALL PROPELLER SHAFT WITH CENTER BEARING ASSEMBLY

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

16. INSTALL FRONT PROPELLER SHAFT ASSEMBLY

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

17. INSTALL TRANSFER CASE LOWER PROTECTOR

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

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

18. INSTALL FRONT EXHAUST PIPE ASSEMBLY

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.

1. Install the front pipe to the pipe support.

1. 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.

1. 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.

19. INSTALL TRANSFER HIGH AND LOW SHIFT LEVER ASSEMBLY

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

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

1. 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.

20. INSTALL SHIFT LEVER BOOT ASSEMBLY

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

21. ADJUST SHIFT LEVER POSITION

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

22. ADD AUTOMATIC TRANSMISSION FLUID

1. Add automatic transmission fluid (Click here)

   Fluid type:
     Toyota Genuine ATF TYPE T-IV

23. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

24. PERFORM INITIALIZATION

1. Perform initialization (Click here).

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

25. INSPECT SHIFT LEVER POSITION

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

26. INSTALL CONSOLE BOX ASSEMBLY

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

27. CHECK FOR EXHAUST GAS LEAKS

28. INSPECT AUTOMATIC TRANSMISSION FLUID

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

29. INSTALL NO. 2 ENGINE UNDER COVER

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

30. INSTALL NO. 1 ENGINE UNDER COVER

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