Avalon 1995-1996

Transaxle Removal & Installation

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  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Remove the battery.
  4.  
  5. Remove the air cleaner assembly.

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    Fig. Automatic transmission and related components

  6.  
  7. Disconnect the throttle cable from the throttle body.
  8.  
  9. Remove the cruise control actuator and bracket.

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    Fig. Remove the cruise control actuator and bracket

  10.  
  11. Remove the ground wire.
  12.  
  13. Disconnect speed sensor connectors, direct clutch speed sensor connector, and the park/neutral position switch connector.
  14.  
  15. Disconnect the solenoid connector.
  16.  
  17. Disconnect the shift control cable from the park/neutral position switch. Remove the nut and disconnect the shift control cable from the control shaft lever.

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    Fig. Remove the nut and disconnect the shift control cable from the control shaft lever

  18.  
  19. Disconnect the ground cable and remove the shift control cable clamp.
  20.  
  21. Disconnect oil cooler hoses.
  22.  
  23. Remove the 2 engine mounting absorber bolts.

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    Fig. Remove the 2 engine mounting absorber bolts

  24.  
  25. Remove the 2 front engine mounting bolts.

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    Fig. Remove the 2 front engine mounting bolts

  26.  
  27. Remove the starter.
  28.  
  29. Remove the exhaust manifold bracket mounting bolt.
  30.  
  31. Remove the 4 transaxle-to-engine bolts.

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    Fig. Remove the 4 transaxle-to-engine bolts

  32.  
  33. Install an engine support fixture. Support the steering gear housing securely to engine support fixture.

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    Fig. Support the steering gear housing

  34.  
  35. Raise and safely support the vehicle.
  36.  
  37. Remove the front wheels.
  38.  
  39. Remove the front exhaust pipe:
    1. Remove the 2 bolts and exhaust front pipe clamp.
    2.  
    3. Remove the 4 nuts.
    4.  
    5. Remove the 2 bolts and exhaust front pipe support.
    6.  
    7. Remove the 2 bolts, nuts, 3 gaskets and exhaust front pipe.
    8.  

  40.  
  41. Remove the transaxle/differential fluid drain plug and gasket. Drain the fluid.
  42.  
  43. Remove the engine side covers and undercovers.
  44.  
  45. Remove both halfshafts.
  46.  
  47. Remove the front side engine mounting insulator bolt.

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    Fig. Remove the front side engine mounting insulator bolt

  48.  
  49. Disconnect the shift control cable.

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    Fig. Disconnect the shift control cable

  50.  
  51. Remove the rear side engine mounting grommets and nuts.

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    Fig. Remove the rear side engine mounting grommets and nuts

  52.  
  53. Remove the 4 left side transaxle mounting bolts.

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    Fig. Remove the 4 left side transaxle mounting bolts

  54.  
  55. Remove the steering gear housing:
    1. Remove the bolts and disconnect the stabilizer bar bushing bracket from the front frame assembly.
    2.  
    3. Remove the 2 steering gear housing mounting bolts and nuts.
    4.  

  56.  
  57. Remove the front frame assembly:
    1. Support the front assembly with a jack.
    2.  
    3. Remove the set screws from the right and left fender liners.
    4.  
    5. Remove the bolts and the power steering reservoir pipe mounting brackets.
    6.  
    7. Remove the, bolts, nuts and the front frame assembly.

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      Fig. Remove the front frame assembly bolts-front



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      Fig. Remove the front frame assembly bolts-rear

    8.  

  58.  
  59. Properly support the transaxle assembly.
  60.  
  61. Remove the torque converter cover.

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    Fig. Remove the torque converter cover

  62.  
  63. Remove the torque converter retaining bolts.

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    Fig. Remove the torque converter bolts

  64.  
  65. Remove the exhaust manifold plate mounting nut.
  66.  
  67. Remove the transaxle-to-engine bolts.

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    Fig. Remove the transaxle-to-engine bolts-right



    Click image to see an enlarged view

    Fig. Remove the transaxle-to-engine bolts-left

  68.  
  69. Carefully remove the transaxle assembly from the vehicle.
  70.  

To install:

  1. Installation is the reverse of removal, noting the following:
    1. Tighten the transaxle-to-engine bolts as follows:

      12mm bolts: 34 ft. lbs. (46 Nm)
       
      17mm bolts: 47 ft. lbs. (64 Nm)
       

    2.  
    3. Tighten the exhaust manifold plate mounting nut to 15 ft. lbs. (20 Nm).
    4.  
    5. Coat the threads of the torque converter bolts with sealer. Install the bolts starting with the black bolt followed by the rest and tighten the bolts evenly to 30 ft. lbs. (41 Nm).
    6.  
    7. Install the front frame assembly and tighten the fasteners as follows:

      14mm bolts: 24 ft. lbs. (32 Nm)
       
      19mm bolts: 134 ft. lbs. (181 Nm)
       
      Nut: 27 ft. lbs. (36 Nm)
       

    8.  
    9. Tighten the power steering reservoir pipe mounting bracket bolts to 7 ft. lbs. (10 Nm).
    10.  
    11. Tighten the steering gear housing mounting bolts and nuts to 134 ft. lbs. (181 Nm).
    12.  
    13. Tighten the stabilizer bar bracket and bolts to 14 ft. lbs. (19 Nm).
    14.  
    15. Tighten the left transaxle mounting bolts and tighten them to 47 ft. lbs. (64 Nm).
    16.  
    17. Tighten the rear side engine mounting nuts to 48 ft. lbs. (66 Nm). Install the grommets.
    18.  
    19. Tighten the front engine mounting insulator bolt to 48 ft. lbs. (66 Nm).
    20.  
    21. Tighten the front exhaust pipe nuts and bolts to 41 ft. lbs. (56 Nm). Use new nuts and gaskets.
    22.  
    23. Tighten the front exhaust pipe support bolts to 14 ft. lbs. (19 Nm).
    24.  
    25. Tighten the front exhaust pipe clamp nuts to 46 ft. lbs. (62 Nm) and bolts to 22 ft. lbs. (29 Nm).
    26.  
    27. Tighten the transaxle-to-engine bolts to 47 ft. lbs. (64 Nm).
    28.  
    29. Tighten the starter mounting bolts to 29 ft. lbs. (39 Nm).
    30.  
    31. Tighten the front side engine mounting bolts to 48 ft. lbs. (66 Nm).
    32.  
    33. Tighten the engine mounting absorber bolts to 35 ft. lbs. (48 Nm).
    34.  
    35. Tighten the shift control cable clamp nut to 11 ft. lbs. (15 Nm).
    36.  
    37. Tighten the throttle cable to 11 ft. lbs. (15 Nm).
    38.  
    39. Check the transaxle/differential fluid level.
    40.  
    41. Check the front wheel alignment.
    42.  

  2.  

 
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