Camry 2008-2009

Transaxle Removal & Installation 2

Print

U250E Automatic Transaxle



Specific to:

Toyota Camry 2007-2008

  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. Place front wheels facing straight ahead.
  6.  
  7. Remove front wheels.
  8.  
  9. Remove both engine under covers.
  10.  
  11. Remove RH front fender apron seal.
  12.  
  13. Drain and recycle the engine coolant.
  14.  
  15. Drain automatic transaxle fluid. Using a 6 mm socket hexagon wrench, remove the drain plug and gasket, and drain ATF. Install a new gasket and drain plug. Tighten the drain plug to 36 ft. lbs. (49 Nm).
  16.  
  17. Remove windshield wiper link assembly.
  18.  
  19. Remove cowl top panel outer sub-assembly.
  20.  
  21. Remove No. 1 engine cover sub-assembly.
  22.  
  23. Remove the drive belt.
  24.  
  25. Remove air cleaner inlet assembly.
  26.  
  27. Remove air cleaner cap sub-assembly.
  28.  
  29. Remove air cleaner case sub-assembly.
  30.  
  31. Remove battery.
  32.  
  33. Remove RH No. 2 engine mounting stay.
  34.  
  35. Remove engine moving control rod sub-assembly.
  36.  
  37. Remove RH No. 2 engine mounting bracket.
  38.  
  39. Disconnect No. 1 vacuum hose connector.
  40.  
  41. Disconnect radiator hose inlet.
  42.  
  43. Disconnect radiator hose outlet.
  44.  
  45. Disconnect oil cooler inlet hose.
  46.  
  47. Disconnect oil cooler outlet hose.
  48.  
  49. Disconnect heater inlet water hose.
  50.  
  51. Disconnect heater outlet water hose.
  52.  
  53. Remove ECM.
  54.  
  55. Disconnect engine wire.
  56.  
  57. Disconnect transmission control cable assembly by performing the following:
    1. Remove the nut from the control shaft lever.
    2.  
    3. Disconnect the transmission control cable assembly from the control shaft lever.
    4.  
    5. Remove the clip and disconnect the transmission control cable assembly from the No. 1 control cable bracket.
    6.  
    7. Disconnect the transmission control cable assembly from the control cable clamp.
    8.  

  58.  
  59. Disconnect No. 1 oil reservoir to pump hose.
  60.  
  61. Disconnect return tube sub-assembly.
  62.  
  63. Disconnect fuel tube sub-assembly.
  64.  
  65. Remove generator assembly.
  66.  
  67. Separate compressor and magnetic clutch.
  68.  
  69. Remove front exhaust pipe assembly.
  70.  
  71. Remove both front axle hub nut.
  72.  
  73. Remove both front stabilizer link assemblies.
  74.  
  75. Remove both front speed sensors.
  76.  
  77. Disconnect both tie rod assemblies.
  78.  
  79. Disconnect both front suspension lower No. 1 arms.
  80.  
  81. Separate both front axle assemblies
  82.  
  83. Remove drive plate and torque converter clutch setting bolt by performing the following:
    1. Remove the flywheel housing under cover.
    2.  
    3. Turn the crankshaft to gain access and remove the 6 bolts while holding the crankshaft pulley bolt with a wrench.
      NOTE
      There will be one green colored bolt.

    4.  

  84.  
  85. Separate steering sliding yoke.
  86.  
  87. Remove engine assembly with transaxle.
  88.  
  89. Remove vane pump assembly.
  90.  
  91. Remove front frame assembly.
  92.  
  93. Remove both front drive shaft assembly.
  94.  
  95. Remove engine wire.
  96.  
  97. Remove starter assembly.
  98.  
  99. Remove the 3 bolts and engine mounting front bracket.
  100.  
  101. Separate automatic transaxle assembly by performing the following:
    1. Remove the 5 bolts
    2.  
    3. Remove the 4 lower side mounting bolts.
    4.  
    5. Separate and remove the automatic transaxle.

      Click image to see an enlarged view

      Fig. Removing 5 bolts-U250E A/T



      Click image to see an enlarged view

      Fig. Removing 4 lower mounting bolts-U250E A/T

    6.  

  102.  
  103. Remove torque converter clutch assembly.
  104.  
  105. Remove speedometer driven hole cover sub-assembly by performing the following:
    1. Remove the bolt and hole cover from the transaxle case
    2.  
    3. Remove the O-ring from the hole cover
    4.  

  106.  
  107. Remove the bolt and No. 2 transmission control cable bracket
  108.  
  109. Disconnect the wire harnesses from the 2 brackets. Remove the 2 bolts and 2 clamps.
  110.  
  111. Remove the bolt and disconnect the wire harness.
  112.  
  113. DISCONNECT transmission electrical CONNECTORS by performing the following:
    1. Disconnect the transmission wire connector.
    2.  
    3. Disconnect the park/neutral position switch connector.
    4.  
    5. Disconnect the 2 speed sensor connectors.

      Click image to see an enlarged view

      Fig. Disconnecting transmission connectors-U250E A/T

    6.  

  114.  
  115. Remove no. 1 transmission control cable bracket by performing the following:
    1. Remove the bolt and oil cooler tube clamp.
    2.  
    3. Remove the 2 bolts and No. 1 transmission control cable bracket.
    4.  

  116.  
  117. Remove transmission oil filler tube sub-assembly by performing the following:
    1. Remove the bolt and transmission oil filler tube sub-assembly.
    2.  
    3. Remove the O-ring from the oil filler tube sub-assembly.
    4.  

  118.  
  119. Using SST 09023-12701 and a wrench, disconnect the No. 1 oil cooler inlet tube.
  120.  
  121. Using SST 09023-12701and a wrench, disconnect the No. 1 oil cooler outlet tube.
  122.  
  123. Remove the 3 bolts and transaxle case upper cover.

    Click image to see an enlarged view

    Fig. Removing 3 bolts and transaxle case upper cover-U250E A/T

  124.  

To install:

  1. Install the transmission case upper cover with the 3 bolts and tighten to: 8 ft. lbs. (12 Nm).
  2.  
  3. Install the engine mounting front bracket to the automatic transaxle with the 3 bolts and tighten to 47 ft. lbs. (64 Nm).
  4.  
  5. Coat a new O-ring with ATF, and install it to the oil filler tube. Install the oil filler tube to the automatic transaxle with the bolt and tighten to 49 inch lbs. (6 Nm).
  6.  
  7. Install the ATF level gauge.
  8.  
  9. Install the No. 1 control cable bracket with the 2 bolts and tighten to 9 ft. lbs. (12 Nm).
  10.  
  11. Install No. 1 oil cooler inlet tube by performing the following:
    1. Temporarily install the No. 1 oil cooler outlet tube.
    2.  
    3. Temporarily install the No. 1 oil cooler inlet tube.
    4.  
    5. Install the oil cooler tube clamp with the bolt and tighten 48 inch lbs. (5 Nm).
    6.  
    7. Using Special Tool: 09023-12701 and a wrench, tighten the No. 1 oil cooler inlet tube to 25 ft. lbs. (34 Nm).
      NOTE
      Use a torque wrench with a fulcrum length of 13.58 inches (345 mm).

    8.  

  12.  
  13. Using Special Tool: 09023-12701 and a wrench, tighten the No. 1 oil cooler outlet tube to 25 ft. lbs. (34 Nm).
    NOTE
    Use a torque wrench with a fulcrum length of 13.58 inches (345 mm).

  14.  
  15. Connect the transmission wire connector. Connect the park/neutral position switch connector. Connect the 2 speed sensor connectors.
  16.  
  17. Connect the wire harness with the bolt and tighten to 9 ft. lbs. (12 Nm).
  18.  
  19. Install the wire harness 2 brackets with the 2 bolts and tighten to 74 inch lbs. (8.4 Nm). Connect the wire harnesses to the clamps.
  20.  
  21. Install the No. 2 transmission control cable bracket with the bolt and tighten 9 ft. lbs. (12 Nm).
  22.  
  23. Coat a new O-ring with ATF WS, and install speedometer driven hole cover sub-assembly to the hole cover and tighten to 47 inch lbs. (6 Nm).
  24.  
  25. Install the torque converter clutch assembly, as follows:
    1. Using vernier calipers and a straight edge, measure dimension "A" between the transaxle fitting part of the engine and the converter fitting part of the drive plate.

      Click image to see an enlarged view

      Fig. Measure dimension "A" between the transaxle fitting part of the engine and the converter fitting part of the drive plate

    2.  
    3. Set the key of the front oil pump drive gear to the top and put a mark on the housing.

      Click image to see an enlarged view

      Fig. Setting the key of the front oil pump drive gear

    4.  
    5. Put a mark on the torque converter clutch so that its groove can be clearly indicated.
    6.  
    7. Align the 2 marks on the transaxle case and torque converter clutch and fit the splined part of the input shaft to the spline part of the turbine runner.
    8.  
    9. Rotating the torque converter clutch, fit the spline part of the stator shaft to the spline part of the stator. Rotate it about 180°.
      CAUTION
      When rotating the torque converter clutch, do not push it with excessive force.

    10.  
    11. 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.
    12.  
    13. Using vernier calipers and a straight edge, measure dimension "B" shown in the illustration and check that "B" is greater than "A" (measured in previous steps) -A- + 1 (0.04 in.) mm or more. Remember to minus the thickness of the straight edge.

      Click image to see an enlarged view

      Fig. Measuring dimension "B"

    14.  

  26.  
  27. Install the automatic transaxle assembly, as follows:
    1. Install the automatic transaxle to the engine with the 5 bolts:

      Bolt A: 47 ft. lbs. (64 Nm)
       
      Bolt B: 34 ft. lbs. (46 Nm)
       
      Bolt C: 34 ft. lbs. (46 Nm)

      Click image to see an enlarged view

      Fig. Automatic transaxle bolt tightening sequence

       

    2.  
    3. Install the 4 lower side mounting bolts and tighten to 32 ft. lbs. (44 Nm).
    4.  

  28.  
  29. Install starter assembly.
  30.  
  31. Install engine wire.
  32.  
  33. Install front drive shaft assembly.
  34.  
  35. Install front frame assembly.
  36.  
  37. Install vane pump assembly.
  38.  
  39. Install engine assembly with transaxle.
  40.  
  41. Install steering sliding yoke.
  42.  
  43. Install the drive plate and torque converter clutch setting bolt, as follows:
    1. Apply a few drops of adhesive (Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent) to 2 threads on the tip of the 6 torque converter clutch mounting bolts.
    2.  
    3. Install the 6 torque converter clutch mounting bolts and tighten to 30 ft. lbs. (41 Nm). First install the black colored bolt, and then the remaining 5 bolts.
    4.  
    5. Install the flywheel housing under cover.
    6.  

  44.  
  45. To complete installation, reverse removal procedure.
  46.  
  47. Tighten control shaft lever nut to 11 ft. lbs. (15 Nm).
  48.  
  49. Add engine coolant.
  50.  
  51. Add automatic transaxle fluid (Toyota Genuine ATF WS).
  52.  
  53. Add power steering fluid.
  54.  
  55. Bleed power steering fluid.
  56.  
  57. Inspect automatic transaxle fluid.
  58.  
  59. Check for fuel leaks.
  60.  
  61. Check for engine coolant leaks.
  62.  
  63. Check for exhaust gas leaks.
  64.  
  65. Check for shift lever position.
  66.  
  67. Adjust shift lever position.
  68.  
  69. Inspect and adjust front wheel alignment.
  70.  
  71. Check ignition timing.
  72.  
  73. Check engine idle speed.
  74.  
  75. Inspect CO/HC.
  76.  
  77. Check abs speed sensor signal.
  78.  

U250E Automatic Transaxle-Non-Hybrid Models



Specific to:

Toyota Camry 2009

  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. Place front wheels facing straight ahead.
  6.  
  7. Remove front wheels.
  8.  
  9. Remove both engine under covers.
  10.  
  11. Remove RH front fender apron seal.
  12.  
  13. Drain and recycle the engine coolant.
  14.  
  15. Drain automatic transaxle fluid. Using a 6 mm socket hexagon wrench, remove the drain plug and gasket, and drain ATF. Install a new gasket and drain plug. Tighten the drain plug to 36 ft. lbs. (49 Nm).
  16.  
  17. Remove windshield wiper link assembly.
  18.  
  19. Remove cowl top panel outer sub-assembly.
  20.  
  21. Remove No. 1 engine cover sub-assembly.
  22.  
  23. Remove the drive belt.
  24.  
  25. Remove air cleaner inlet assembly.
  26.  
  27. Remove air cleaner cap sub-assembly.
  28.  
  29. Remove air cleaner case sub-assembly.
  30.  
  31. Remove battery.
  32.  
  33. Remove RH No. 2 engine mounting stay.
  34.  
  35. Remove engine moving control rod sub-assembly.
  36.  
  37. Remove RH No. 2 engine mounting bracket.
  38.  
  39. Disconnect No. 1 vacuum hose connector.
  40.  
  41. Disconnect radiator hose inlet.
  42.  
  43. Disconnect radiator hose outlet.
  44.  
  45. Disconnect oil cooler inlet hose.
  46.  
  47. Disconnect oil cooler outlet hose.
  48.  
  49. Disconnect heater inlet water hose.
  50.  
  51. Disconnect heater outlet water hose.
  52.  
  53. Remove ECM.
  54.  
  55. Disconnect engine wire.
  56.  
  57. Disconnect transmission control cable assembly by performing the following:
    1. Remove the nut from the control shaft lever.
    2.  
    3. Disconnect the transmission control cable assembly from the control shaft lever.
    4.  
    5. Remove the clip and disconnect the transmission control cable assembly from the No. 1 control cable bracket.
    6.  
    7. Disconnect the transmission control cable assembly from the control cable clamp.
    8.  

  58.  
  59. Disconnect No. 1 oil reservoir to pump hose.
  60.  
  61. Disconnect return tube sub-assembly.
  62.  
  63. Disconnect fuel tube sub-assembly.
  64.  
  65. Remove generator assembly.
  66.  
  67. Separate compressor and magnetic clutch.
  68.  
  69. Remove front exhaust pipe assembly.
  70.  
  71. Remove both front axle hub nut.
  72.  
  73. Remove both front stabilizer link assemblies.
  74.  
  75. Remove both front speed sensors.
  76.  
  77. Disconnect both tie rod assemblies.
  78.  
  79. Disconnect both front suspension lower No. 1 arms.
  80.  
  81. Separate both front axle assemblies
  82.  
  83. Remove drive plate and torque converter clutch setting bolt by performing the following:
    1. Remove the flywheel housing under cover.
    2.  
    3. Turn the crankshaft to gain access and remove the 6 bolts while holding the crankshaft pulley bolt with a wrench.
      NOTE
      There will be one green colored bolt.

    4.  

  84.  
  85. Separate steering sliding yoke.
  86.  
  87. Remove engine assembly with transaxle.
  88.  
  89. Remove vane pump assembly.
  90.  
  91. Remove front frame assembly.
  92.  
  93. Remove both front drive shaft assembly.
  94.  
  95. Remove engine wire.
  96.  
  97. Remove starter assembly.
  98.  
  99. Remove the 3 bolts and engine mounting front bracket.
  100.  
  101. Separate automatic transaxle assembly by performing the following:
    1. Remove the 5 bolts
    2.  
    3. Remove the 4 lower side mounting bolts.
    4.  
    5. Separate and remove the automatic transaxle.

      Click image to see an enlarged view

      Fig. Removing 5 bolts-U250E A/T



      Click image to see an enlarged view

      Fig. Removing 4 lower mounting bolts-U250E A/T

    6.  

  102.  
  103. Remove torque converter clutch assembly.
  104.  
  105. Remove speedometer driven hole cover sub-assembly by performing the following:
    1. Remove the bolt and hole cover from the transaxle case
    2.  
    3. Remove the O-ring from the hole cover
    4.  

  106.  
  107. Remove the bolt and No. 2 transmission control cable bracket
  108.  
  109. Disconnect the wire harnesses from the 2 brackets. Remove the 2 bolts and 2 clamps.
  110.  
  111. Remove the bolt and disconnect the wire harness.
  112.  
  113. DISCONNECT transmission electrical CONNECTORS by performing the following:
    1. Disconnect the transmission wire connector.
    2.  
    3. Disconnect the park/neutral position switch connector.
    4.  
    5. Disconnect the 2 speed sensor connectors.

      Click image to see an enlarged view

      Fig. Disconnecting transmission connectors-U250E A/T

    6.  

  114.  
  115. Remove no. 1 transmission control cable bracket by performing the following:
    1. Remove the bolt and oil cooler tube clamp.
    2.  
    3. Remove the 2 bolts and No. 1 transmission control cable bracket.
    4.  

  116.  
  117. Remove transmission oil filler tube sub-assembly by performing the following:
    1. Remove the bolt and transmission oil filler tube sub-assembly.
    2.  
    3. Remove the O-ring from the oil filler tube sub-assembly.
    4.  

  118.  
  119. Using SST 09023-12701 and a wrench, disconnect the No. 1 oil cooler inlet tube.
  120.  
  121. Using SST 09023-12701and a wrench, disconnect the No. 1 oil cooler outlet tube.
  122.  
  123. Remove the 3 bolts and transaxle case upper cover.

    Click image to see an enlarged view

    Fig. Removing 3 bolts and transaxle case upper cover-U250E A/T

  124.  

To install:

  1. Install the transmission case upper cover with the 3 bolts and tighten to: 8 ft. lbs. (12 Nm).
  2.  
  3. Install the engine mounting front bracket to the automatic transaxle with the 3 bolts and tighten to 47 ft. lbs. (64 Nm).
  4.  
  5. Coat a new O-ring with ATF, and install it to the oil filler tube. Install the oil filler tube to the automatic transaxle with the bolt and tighten to 49 inch lbs. (6 Nm).
  6.  
  7. Install the ATF level gauge.
  8.  
  9. Install the No. 1 control cable bracket with the 2 bolts and tighten to 9 ft. lbs. (12 Nm).
  10.  
  11. Install No. 1 oil cooler inlet tube by performing the following:
    1. Temporarily install the No. 1 oil cooler outlet tube.
    2.  
    3. Temporarily install the No. 1 oil cooler inlet tube.
    4.  
    5. Install the oil cooler tube clamp with the bolt and tighten 48 inch lbs. (5 Nm).
    6.  
    7. Using Special Tool: 09023-12701 and a wrench, tighten the No. 1 oil cooler inlet tube to 25 ft. lbs. (34 Nm).
      NOTE
      Use a torque wrench with a fulcrum length of 13.58 inches (345 mm).

    8.  

  12.  
  13. Using Special Tool: 09023-12701 and a wrench, tighten the No. 1 oil cooler outlet tube to 25 ft. lbs. (34 Nm).
    NOTE
    Use a torque wrench with a fulcrum length of 13.58 inches (345 mm).

  14.  
  15. Connect the transmission wire connector. Connect the park/neutral position switch connector. Connect the 2 speed sensor connectors.
  16.  
  17. Connect the wire harness with the bolt and tighten to 9 ft. lbs. (12 Nm).
  18.  
  19. Install the wire harness 2 brackets with the 2 bolts and tighten to 74 inch lbs. (8.4 Nm). Connect the wire harnesses to the clamps.
  20.  
  21. Install the No. 2 transmission control cable bracket with the bolt and tighten 9 ft. lbs. (12 Nm).
  22.  
  23. Coat a new O-ring with ATF WS, and install speedometer driven hole cover sub-assembly to the hole cover and tighten to 47 inch lbs. (6 Nm).
  24.  
  25. Install the torque converter clutch assembly, as follows:
    1. Using vernier calipers and a straight edge, measure dimension "A" between the transaxle fitting part of the engine and the converter fitting part of the drive plate.

      Click image to see an enlarged view

      Fig. Measure dimension "A" between the transaxle fitting part of the engine and the converter fitting part of the drive plate

    2.  
    3. Set the key of the front oil pump drive gear to the top and put a mark on the housing.

      Click image to see an enlarged view

      Fig. Setting the key of the front oil pump drive gear

    4.  
    5. Put a mark on the torque converter clutch so that its groove can be clearly indicated.
    6.  
    7. Align the 2 marks on the transaxle case and torque converter clutch and fit the splined part of the input shaft to the spline part of the turbine runner.
    8.  
    9. Rotating the torque converter clutch, fit the spline part of the stator shaft to the spline part of the stator. Rotate it about 180°.
      CAUTION
      When rotating the torque converter clutch, do not push it with excessive force.

    10.  
    11. 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.
    12.  
    13. Using vernier calipers and a straight edge, measure dimension "B" shown in the illustration and check that "B" is greater than "A" (measured in previous steps) -A- + 1 (0.04 in.) mm or more. Remember to minus the thickness of the straight edge.

      Click image to see an enlarged view

      Fig. Measuring dimension "B"

    14.  

  26.  
  27. Install the automatic transaxle assembly, as follows:
    1. Install the automatic transaxle to the engine with the 5 bolts:

      Bolt A: 47 ft. lbs. (64 Nm)
       
      Bolt B: 34 ft. lbs. (46 Nm)
       
      Bolt C: 34 ft. lbs. (46 Nm)

      Click image to see an enlarged view

      Fig. Automatic transaxle bolt tightening sequence

       

    2.  
    3. Install the 4 lower side mounting bolts and tighten to 32 ft. lbs. (44 Nm).
    4.  

  28.  
  29. Install starter assembly.
  30.  
  31. Install engine wire.
  32.  
  33. Install front drive shaft assembly.
  34.  
  35. Install front frame assembly.
  36.  
  37. Install vane pump assembly.
  38.  
  39. Install engine assembly with transaxle.
  40.  
  41. Install steering sliding yoke.
  42.  
  43. Install the drive plate and torque converter clutch setting bolt, as follows:
    1. Apply a few drops of adhesive (Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent) to 2 threads on the tip of the 6 torque converter clutch mounting bolts.
    2.  
    3. Install the 6 torque converter clutch mounting bolts and tighten to 30 ft. lbs. (41 Nm). First install the black colored bolt, and then the remaining 5 bolts.
    4.  
    5. Install the flywheel housing under cover.
    6.  

  44.  
  45. To complete installation, reverse removal procedure.
  46.  
  47. Tighten control shaft lever nut to 11 ft. lbs. (15 Nm).
  48.  
  49. Add engine coolant.
  50.  
  51. Add automatic transaxle fluid (Toyota Genuine ATF WS).
  52.  
  53. Add power steering fluid.
  54.  
  55. Bleed power steering fluid.
  56.  
  57. Inspect automatic transaxle fluid.
  58.  
  59. Check for fuel leaks.
  60.  
  61. Check for engine coolant leaks.
  62.  
  63. Check for exhaust gas leaks.
  64.  
  65. Check for shift lever position.
  66.  
  67. Adjust shift lever position.
  68.  
  69. Inspect and adjust front wheel alignment.
  70.  
  71. Check ignition timing.
  72.  
  73. Check engine idle speed.
  74.  
  75. Inspect CO/HC.
  76.  
  77. Check abs speed sensor signal.
  78.  

U660E Automatic Transaxle



Specific to:

Toyota Camry 2007-2008


NOTE
When the automatic transaxle is replaced, the transaxle's compensation code must be input into the


NOTE
TCM. When the TCM is replaced, the existing transaxle compensation codes must be input into the new TCM.


NOTE
If the valve body assembly has been replaced, initialize the TCM and perform a road test to allow the TCM to learn.


NOTE
If the shift solenoid SL1 has been replaced, perform a road test to allow the TCM to learn.


NOTE
If the TCM or transaxle has been replaced, register the transmission compensation code in the TCM.


NOTE
Perform RESET MEMORY (A/T initialization) when replacing the automatic transmission assembly, engine assembly or ECM.

  1. Before servicing the vehicle, refer to the Precautions Section.
    CAUTION
    Observe all applicable safety precautions when working around fuel. Whenever servicing the fuel system, always work in a well ventilated area. Do not allow fuel spray or vapors to come in contact with a spark or open flame. Keep a dry chemical fire extinguisher near the work area. Always keep fuel in a container specifically designed for fuel storage; also, always properly seal fuel containers to avoid the possibility of fire or explosion.

  2.  
  3. Discharge the fuel system pressure.
  4.  
  5. Disconnect cable from negative battery terminal.
  6.  
  7. Place front wheels facing straight ahead.
  8.  
  9. Remove front wheels.
  10.  
  11. Remove the right and left engine under covers.
  12.  
  13. Remove the right front fender apron seal.
  14.  
  15. Drain engine coolant.
  16.  
  17. Drain automatic transaxle fluid, as follows:
    1. Remove the refill plug and gasket.
    2.  
    3. Using a 6 mm socket hexagon wrench, remove the overflow plug and gasket.
    4.  
    5. Using a 6 mm socket hexagon wrench, remove the No. 1 transmission oil filler tube.

      Click image to see an enlarged view

      Fig. Remove the No. 1 transmission oil filler tube

    6.  
    7. Drain the automatic transaxle fluid.
    8.  
    9. Using a 6 mm socket hexagon wrench, install the No. 1 transmission oil filler tube and tighten to 15 inch lbs. (1.7 Nm).
    10.  
    11. Using a 6 mm socket hexagon wrench, install the overflow plug with a new gasket and tighten to 30 ft. lbs. (40 Nm).
    12.  
    13. Install the refill plug with a new gasket and tighten to 36 ft. lbs. (49 Nm).
    14.  

  18.  
  19. Remove windshield wiper link assembly.
  20.  
  21. Remove the cowl top panel outer sub-assembly.
  22.  
  23. Remove the cool air intake duct seal.
  24.  
  25. Remove the V-bank cover sub-assembly.
  26.  
  27. Remove the V-ribbed belt.
  28.  
  29. Remove air cleaner inlet assembly.
  30.  
  31. Remove air cleaner cap sub-assembly.
  32.  
  33. Remove air cleaner case sub-assembly.
  34.  
  35. Remove the No. 1 air cleaner inlet.
  36.  
  37. Remove the battery.
  38.  
  39. Remove the intake air resonator sub-assembly.
  40.  
  41. Remove the right No. 2 engine mounting stay.
  42.  
  43. Remove the engine moving control rod sub-assembly.
  44.  
  45. Disconnect the No. 1 fuel vapor feed hose.
  46.  
  47. Disconnect check valve to brake booster hose.
  48.  
  49. Disconnect the radiator inlet and outlet hoses.
  50.  
  51. Disconnect the No. 1 oil cooler inlet and outlet hoses.
  52.  
  53. Disconnect the heater water inlet hose.
  54.  
  55. Disconnect the heater water outlet hose.
  56.  
  57. Remove the ECM.
  58.  
  59. Remove the upper relay block cover.
  60.  
  61. Disconnect the engine wire.
  62.  
  63. Remove the bolt and disconnect the wire harness.
  64.  
  65. Disconnect the park/neutral position switch connector.
  66.  
  67. Disconnect the transmission control cable assembly, as follows:
    1. Remove the nut from the control shaft lever.
    2.  
    3. Disconnect the transmission control cable assembly from the control shaft lever.
    4.  
    5. Remove the clip and disconnect the transmission control cable assembly from the No. 1 transmission control cable bracket.
    6.  

  68.  
  69. Separate the fuel tube sub-assembly.
  70.  
  71. Disconnect the No. 1 oil reservoir to pump hose.
  72.  
  73. Disconnect return tube sub-assembly.
  74.  
  75. Remove the No. 1 exhaust pipe support bracket.
  76.  
  77. Remove front exhaust pipe assembly.
  78.  
  79. Remove both front axle hub nuts.
  80.  
  81. Disconnect both front stabilizer link assemblies.
  82.  
  83. Disconnect the left and right front speed sensors.
  84.  
  85. Separate the left and right tie rod end sub-assemblies.
  86.  
  87. Separate the left and right front lower No. 1 suspension arm sub-assemblies.
  88.  
  89. Separate the left and right front axle assemblies.
  90.  
  91. Remove the front No. 1 exhaust pipe support bracket.
  92.  
  93. Remove the 2 bolts, exhaust pipe support bracket and flywheel housing under cover.

    Click image to see an enlarged view

    Fig. Removing the 2 bolts, exhaust pipe support bracket and flywheel housing under cover

  94.  
  95. Remove drive plate and torque converter clutch setting bolt, as follows:
    1. Turn the crankshaft to gain access and remove the 6 bolts while holding the crankshaft pulley bolt with a wrench.

      Click image to see an enlarged view

      Fig. Removing drive plate and torque converter clutch setting bolt

    2.  

  96.  
  97. Disconnect steering sliding yoke.
  98.  
  99. Remove generator assembly.
  100.  
  101. Separate cooler compressor assembly.
  102.  
  103. Remove engine assembly with transaxle.
  104.  
  105. Remove vane pump assembly.
  106.  
  107. Install engine hangers.
  108.  
  109. Remove front frame assembly.
  110.  
  111. Remove both front drive shaft assemblies.
  112.  
  113. Remove engine wire.
  114.  
  115. Remove starter assembly.
  116.  
  117. Remove the automatic transaxle assembly, as follows:
    1. Remove the bolt and breather bracket from the left camshaft housing sub-assembly.
    2.  
    3. Remove the breather hose from the breather bracket.
    4.  
    5. Remove the 11 bolts.
    6.  
    7. Separate and remove the automatic transaxle.

      Click image to see an enlarged view

      Fig. Removing the 11 bolts

    8.  

  118.  
  119. Put matchmarks on the transaxle housing and torque converter clutch assembly.
  120.  
  121. Remove the torque converter clutch assembly from the automatic transaxle assembly.
  122.  
  123. Remove the 3 bolts and engine mounting front bracket.
  124.  
  125. Remove the 2 bolts and TCM from the transaxle.
  126.  
  127. Remove the speedometer driven hole cover sub-assembly, as follows:
    1. Remove the bolt and hole cover from the transaxle case.
    2.  
    3. Remove the O-ring from the hole cover.
    4.  

  128.  
  129. Remove the wire harness clamp bracket, as follows:
    1. Remove the 4 bolts and 4 clamp brackets.
    2.  

  130.  
  131. Remove the 2 bolts and No. 1 transmission control cable bracket.
  132.  
  133. Separate the No. 1 oil cooler inlet and outlet hoses.
  134.  

To install:

  1. Inspect the torque converter clutch assembly.
  2.  
  3. Install the torque converter clutch assembly, as follows:
    1. Engage the splines of the input shaft and turbine runner.
    2.  
    3. Engage the splines of the stator shaft and the stator while turning the torque converter clutch assembly.
      NOTE
      If the stator shaft splines are difficult to engage with the stator splines, move the torque converter back approximately 10 mm (0.40 in.) and engage the splines while rotating the torque converter.

    4.  
    5. Turn the torque converter clutch assembly to engage the key of the oil pump drive gear into the slot on the torque converter clutch assembly.
    6.  
    7. Using a vernier caliper and a straightedge, measure dimension "A" between the transaxle fitting part of the engine and the converter fitting part of the drive plate.

      Click image to see an enlarged view

      Fig. Measure dimension "A" between the transaxle fitting part of the engine and the converter fitting part of the drive plate

    8.  
    9. Using a vernier caliper and a straightedge, measure dimension "B" shown in the illustration and check that "B" is greater than "A" (measured in previous step). Standard: A + 1 mm (0.04 in.) or more.
      NOTE
      Make sure to deduct the thickness of the straightedge.


      NOTE
      If the transaxle is installed to the engine with the torque converter not sufficiently inserted, the torque converter may be damaged.


      NOTE
      In the case of where a U660E is used with a 2GR-FE, the standard installation depth is 0.55 inches (14 mm) or more.



      Click image to see an enlarged view

      Fig. Measure dimension "B" shown in the illustration and check that "B" is greater than "A"

    10.  

  4.  
  5. Install the No. 1 oil cooler inlet and outlet hoses.
  6.  
  7. Install the No. 1 transmission control cable bracket with the 2 bolts and tighten to 9 ft. lbs. (12 Nm).
  8.  
  9. Install the 4 clamp brackets and 4 bolts and tighten to 74 inch lbs. (8.4 Nm).
  10.  
  11. Install the speedometer driven hole cover sub-assembly, as follows:
    1. Coat a new O-ring with ATF, and install it to the hole cover.
    2.  
    3. Install the hole cover to the transaxle case with the bolt and tighten to 49 inch lbs. (5.5 Nm).
    4.  

  12.  
  13. Install the TCM, as follows:
    1. Install the TCM to the automatic transaxle assembly.
    2.  
    3. Install and tighten the 2 bolts in the order shown in the illustration to 9 ft. lbs. (11 Nm).

      Click image to see an enlarged view

      Fig. TCM bolt tightening sequence

    4.  

  14.  
  15. Install the engine mounting front bracket to the automatic transaxle with the 3 bolts and tighten to 47 ft. lbs. (64 Nm).
  16.  
  17. Install the automatic transaxle assembly, as follows:
    1. Install the automatic transaxle to the engine with the 11 bolts and tighten to:
      NOTE
      Make sure that the 2 knock pins are installed on the engine before installing the transaxle.



      A: 47 ft. lbs. (64 Nm)
       
      B: 47 ft. lbs. (64 Nm)
       
      C: 34 ft. lbs. (46 Nm)
       
      D: 32 ft. lbs. (43 Nm)

      Click image to see an enlarged view

      Fig. Automatic transaxle bolt sequence

       

    2.  
    3. Install the breather bracket to the camshaft housing sub-assembly with the bolt and tighten to 49 inch lbs. (5.5 Nm).
    4.  
    5. Install the breather hose to the breather bracket.
    6.  

  18.  
  19. Install starter assembly.
  20.  
  21. Connect the park/neutral position switch connector.
  22.  
  23. Connect the wire harness with the bolt and tighten to 9 ft. lbs. (12 Nm).
  24.  
  25. Install the engine wire.
  26.  
  27. Install the left and right front drive shaft assemblies.
  28.  
  29. Install the front frame assembly.
  30.  
  31. Install the vane pump assembly.
  32.  
  33. Install the engine assembly with transaxle.
  34.  
  35. Install the cooler compressor assembly.
  36.  
  37. Install the generator assembly.
  38.  
  39. Install the steering sliding yoke.
  40.  
  41. Install the drive plate and torque converter clutch setting bolt, as follows:
    1. Apply a few drops of adhesive (Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent) to 2 threads on the tip of the 6 torque converter clutch mounting bolts.
    2.  
    3. Install the 6 torque converter clutch mounting bolts and tighten to 30 ft. lbs. (41 Nm). First install the black colored bolt, and then the remaining 5 bolts.
    4.  

  42.  
  43. Install the flywheel housing under cover and exhaust pipe support bracket to the automatic transaxle with the 2 bolts tighten to 69 inch lbs. (7.8 Nm).
  44.  
  45. Install the No. 1 exhaust pipe support bracket.
  46.  
  47. Install the left and right front axle assemblies.
  48.  
  49. Install the left and right front lower No. 1 suspension arm sub-assemblies.
  50.  
  51. Install the left and right tie rod end sub-assemblies.
  52.  
  53. Install the left and right front speed sensors.
  54.  
  55. Install the left and right front stabilizer link assemblies.
  56.  
  57. Install the left and right front axle shaft nuts.
  58.  
  59. Install the front exhaust pipe assembly.
  60.  
  61. Install the No. 1 exhaust pipe support bracket.
  62.  
  63. Connect the steering gear outlet return tube.
  64.  
  65. Connect the No. 1 oil reservoir to pump hose.
  66.  
  67. Connect the transmission control cable assembly, as follows:
    1. Install the transmission control cable assembly to the control shaft lever with the nut and tighten to 10 ft. lbs. (13 Nm).
    2.  
    3. Connect the transmission control cable assembly with a new clip to the No. 1 transmission control cable bracket.
    4.  

  68.  
  69. To complete installation, reverse remaining removal procedure.
  70.  
  71. Connect the negative battery cable.
  72.  
  73. Add coolant and power steering fluid.
  74.  
  75. Bleed the power steering system.
  76.  
  77. Add automatic transaxle fluid.
  78.  
  79. Inspect and adjust shift lever position.
  80.  
  81. Inspect for coolant leak, fuel leak, and exhaust gas leak.
  82.  
  83. Inspect ignition timing.
  84.  
  85. Inspect the engine idle speed.
  86.  
  87. Check the function of throttle body.
  88.  
  89. Install the V-bank cover sub-assembly.
  90.  
  91. Install the cool air intake duct seal.
  92.  
  93. Inspect CO/HC.
  94.  
  95. Inspect the ABS speed sensor signal.
  96.  
  97. Inspect and adjust front wheel alignment.
  98.  
  99. Install the right front fender apron seal.
  100.  
  101. Install the right and left engine under covers.
  102.  

 
label.common.footer.alt.autozoneLogo