Toyota Pick-ups/Land Cruiser/4Runner 1989-1996

Transmission Assembly

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REMOVAL & INSTALLATION



Pick-Up and 4Runner
A43D, A44D AND A340E

See Figures 1, 2, 3 and 4



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Fig. Fig. 1: To help ensure proper installation, measure the distance between the torque converter mounting lugs and the front mounting face of the transmission

  1. Disconnect the cables at the battery, negative first.
  2.  
  3. Remove the air cleaner assembly.
  4.  
  5. Disconnect the transmission throttle cable.
  6.  



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Fig. Fig. 2: Exploded view of the A43D transmission and components to be removed



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Fig. Fig. 3: Exploded view of the A44D transmission and components to be removed



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Fig. Fig. 4: Exploded view of the A340E transmission and components to be removed

  1. Raise the vehicle and support it safely with jackstands. Double check the security and placement of the stands.
  2.  
  3. Unplug the wiring connectors near the starter.
  4.  
  5. Disconnect the starter wiring at the starter. Unbolt the starter and remove it from the vehicle.
  6.  
  7. Drain the transmission fluid.
  8.  
  9. Matchmark the rear driveshaft flange and the differential pinion flange. These marks must be aligned during installation.
  10.  
  11. Unbolt the rear driveshaft flange. If the vehicle has a two piece driveshaft, remove the center bearing bracket-to-frame bolts. Remove the driveshaft from the vehicle.
  12.  
  13. Disconnect the speedometer cable from the transmission and tie it out of the way.
  14.  
  15. Disconnect the shift linkage at the transmission.
  16.  
  17. Disconnect the exhaust pipe clamp at the bell housing and remove the transmission dipstick and oil filler tube.
  18.  
  19. Disconnect the transmission oil cooler lines at the transmission.
  20.  
  21. Support the transmission using a jack with a wooden block placed between the jack and the transmission pan. Do not raise the transmission, just raise the jack until the wooden block touches the transmission pan.
  22.  
  23. Place a wooden block (or blocks) between the engine oil pan and the front frame crossmember.
  24.  

The wooden block(s) should be no more than about 0.2 in. (6mm) away from the engine so that when the engine is lowered, damage will not occur to any underhood components.

  1. Remove the transmission mount-to-crossmember bolts.
  2.  
  3. Raise the transmission SLIGHTLY, just enough to take the weight of the transmission off of the crossmember. Remove the crossmember-to-frame mounting bolts and remove the crossmember from the vehicle. For vehicles with the A43D, remove the bracket and rear transmission mount.
  4.  
  5. Slowly lower the transmission until the engine rests on the wooden block placed earlier.
  6.  
  7. Remove the engine undercover in order to gain access to the engine crankshaft pulley.
  8.  
  9. Remove the rubber plugs from the service holes located at the rear of the engine in order to gain access to the torque converter bolts.
  10.  
  11. Rotate the crankshaft as necessary to remove the torque converter retaining bolts. Access to these bolts is through the service holes mentioned earlier.
  12.  
  13. Obtain a bolt of the same dimensions as the torque converter bolts. Cut the head off of the bolt and cut a screwdriver slot in the bolt opposite the threaded end.
  14.  

This modified bolt is used as a guide pin. Two guide pins are needed to properly install the transmission.

  1. Thread the guide pin into one of the torque converter bolt holes. The guide pin will help keep the converter with the transmission.
  2.  
  3. Remove the transmission-to-engine mounting bolts.
  4.  
  5. Carefully move the transmission rearward by prying on the guide pin through the service hole.
  6.  

As soon as the transmission is away from the engine about 0.1 in. (3mm), feed wire through the front of the transmission and secure the wire in order to keep the converter attached to the transmission. Also, try to keep the nose of the transmission pointed upward SLIGHTLY to help keep the converter in place.

  1. Pull the transmission rearward and lower it out of the vehicle.
  2.  

Do not allow the attached cables to catch on any components during removal.

  1. With the transmission out of the vehicle, remove the torque converter as follows:
    1. Place a drain pan under the front of the transmission.
    2.  
    3. Pull the converter straight off the transmission and allow the fluid to drain.
    4.  

  2.  

Prior to installation of the transmission, Toyota recommends checking the torque converter and flywheel run-out dimensions. If either of these run-out limits are beyond the maximum allowable limits, excessive wear of the front transmission seal will occur.

  1. Mount the torque converter on the flywheel and tighten the converter bolts to 20 ft. lbs. (27 Nm) for A43D and A44D transmissions. For A340E, tighten them to 30 ft. lbs. (41 Nm).
  2.  
  3. Mount the dial indicator so that the indicator probe touches the outer surface of the converter extension sleeve (90° to the converter centerline).
  4.  
  5. Adjust the dial indicator to zero.
  6.  
  7. Slowly rotate the converter and read the dial indicator. The indicator needle should not deviate more than 0.01 in. (0.30mm).
  8.  
  9. Remove the torque converter from the flywheel.
  10.  
  11. Mount the dial indicator so that the indicator probe touches the flywheel ring gear just inside of the gear teeth (surface faces the rear of the vehicle).
  12.  
  13. Zero the indicator needle and slowly rotate the flywheel. The indicator needle should not deviate more than 0.01 in. (0.20mm).
  14.  

To install:
  1. Apply a coat of multi-purpose grease to the torque converter stub shaft and the corresponding pilot hole in the flywheel.
  2.  
  3. Install the torque converter into the front of the transmission. Push inward on the torque converter while rotating it to completely couple the torque converter to the transmission.
  4.  
  5. To make sure that the converter is properly installed, measure the distance between the torque converter mounting lugs and the front mounting face of the transmission. The proper distance is 0.79 in. (20mm) for A43D and A44D; for A340E, correct distance is 0.71 in. (18mm).
  6.  
  7. Install the guide pins into two opposite mounting lugs of the torque converter.
  8.  
  9. Raise the transmission to the engine and align the transmission with the engine alignment dowels. Also, position the converter guide pins into the mounting holes of the flywheel.
  10.  
  11. Install and tighten the transmission-to-engine mounting bolts. Tighten the bolts to 47 ft. lbs. (64 Nm).
  12.  
  13. Remove the converter guide pins and install the converter mounting bolts. Rotate the crankshaft as necessary to gain access to the guide pins and bolts through the service holes.
  14.  
  15. Evenly tighten the converter mounting bolts to 20 ft. lbs. (27 Nm) for A43D and A44D transmissions. For A340E transmissions, tighten them to 30 ft. lbs. (41 Nm). Install the rubber plugs into the access holes.
  16.  
  17. Install the engine undercover.
  18.  
  19. Raise the transmission slightly and remove the wood block(s) from beneath the engine oil pan.
  20.  
  21. Install the transmission crossmember. Tighten the crossmember-to-frame bolts to 70 ft. lbs. (95 Nm). For A43D transmissions, install the rear mounting bracket and tighten the bolts to 43 ft. lbs. (58 Nm).
  22.  
  23. Lower the transmission onto the crossmember and install the transmission mounting bolts. Tighten the bolts to 18 ft. lbs. (25 Nm).
  24.  
  25. Install the oil filler tube and connect the exhaust pipe clamp.
  26.  
  27. Connect the oil cooler lines to the transmission and tighten the fittings to 23 ft. lbs. (31 Nm).
  28.  
  29. Connect the shift linkage and the speedometer cable.
  30.  
  31. Install the driveshaft and the starter.
  32.  
  33. Connect the wiring harnesses.
  34.  
  35. Connect and adjust the transmission throttle cable.
  36.  
  37. Install the air cleaner assembly and connect the battery cables.
  38.  
  39. Fill the transmission with the correct fluid. If the torque converter was completely drained, the transmission will need about 7 quarts of fluid.
  40.  
  41. Road test the vehicle and check for leaks.
  42.  

A340F AND A340H

See Figure 5

  1. Disconnect the negative battery cable.
  2.  
  3. Unplug the air intake connector.
  4.  



Click image to see an enlarged view

Fig. Fig. 5: Exploded view of the A340F transmission and components to be removed

  1. Loosen the adjusting nuts and disconnect the throttle cable housing at the bracket. Disconnect the cable at the linkage, then unplug it from the rear of the engine.
  2.  
  3. Underneath the air intake chamber there are 5 connectors; unplug them.
  4.  
  5. Remove the upper starter mounting bolt.
  6.  
  7. Raise the vehicle, support it on safety stands and drain the transmission fluid.
  8.  
  9. Remove the driveshafts.
  10.  
  11. Disconnect the exhaust pipe at the tail pipe.
  12.  
  13. Disconnect and plug the 2 oil cooler lines at the transmission case.
  14.  
  15. Pull out the cotter pin and disconnect the manual shift linkage at the neutral safety switch.
  16.  
  17. Pull the cotter pins and disconnect the No. 1 and No. 2 transfer case shift linkages at the cross shaft over the transmission case. Remove the cross shaft.
  18.  
  19. Disconnect the speedometer cable.
  20.  
  21. Disconnect the 2 oil cooler lines at the transfer case.
  22.  
  23. Using a transmission jack, or a floor jack and a block of wood, raise the transmission just enough to remove pressure from the rear support member.
  24.  
  25. Position a piece of wood between the firewall and the rear of the cylinder head, remove the 8 bolts and lift out the rear support member.
  26.  
  27. Remove the engine under cover.
  28.  
  29. Remove the 6 torque converter mounting bolts.
  30.  

Rotate the crankshaft in order to gain access to the torque converter mounting bolts.

  1. Insert a guide pin (just cut off the head of an old bolt) into one of the torque converter bolt holes.
  2.  
  3. Remove the starter and then remove the transmission housing mounting bolts.
  4.  
  5. Using the guide pin to keep the transmission and torque converter together, pry on the end of the pin to get the transmission assembly moving rearward. Be careful!
  6.  
  7. With a large drip pan under the assembly, pull off the converter. Remove the filler tube from the side of the transmission case.
  8.  

Prior to installation of the transmission, Toyota recommends checking the torque converter and flywheel run-out dimensions. If either of these run-out limits are beyond the maximum allowable limits, excessive wear of the front transmission seal will occur.

  1. Mount the torque converter on the flywheel and tighten the converter bolts to 30 ft. lbs. (40 Nm).
  2.  
  3. Mount the dial indicator so that the indicator probe touches the outer surface of the converter extension sleeve (90° to the converter centerline).
  4.  
  5. Adjust the dial indicator to zero.
  6.  
  7. Slowly rotate the converter and read the dial indicator. The indicator needle should not deviate more than 0.01 in. (0.30mm).
  8.  
  9. Remove the torque converter from the flywheel.
  10.  
  11. Mount the dial indicator so that the indicator probe touches the flywheel ring gear just inside of the gear teeth (surface faces the rear of the vehicle).
  12.  
  13. Zero the indicator needle and slowly rotate the flywheel. The indicator needle should not deviate more than 0.01 in. (0.20mm).
  14.  

To install:
  1. Use a new O-ring and press the filler tube into the transmission case.
  2.  
  3. Coat the pilot hole in the crankshaft and the center hub of the converter with grease.
  4.  
  5. Install the torque converter into the transmission case. Using calipers and a straightedge, make sure the distance from the installed surface of the converter to the transmission housing lip is 1.02 in. (26mm).
  6.  
  7. Install a guide pin in the converter and align it with one of the driveplate holes. Align the 2 sleeves on the cylinder block with the converter housing and temporarily install a bolt.
  8.  


WARNING
Never tilt the transmission forward during installation; the converter will fall out.

  1. If all holes are aligned, install the starter and then all remaining transmission housing bolts. Tighten to 47 ft. lbs. (64 Nm).
  2.  
  3. Remove the guide pin and install the 6 converter bolts. Tighten the bolts evenly to 20 ft. lbs. (27 Nm) on models with 4 cylinder engines and to 30 ft. lbs. (41 Nm) on those with the V6.
  4.  
  5. Install the engine under cover.
  6.  
  7. Install the rear support member and tighten the 8 bolts to 70 ft. lbs. (95 Nm).
  8.  
  9. Connect the transfer case oil cooler lines.
  10.  
  11. Connect the speedometer cable being sure that the washer and felt dust protector are still on the end.
  12.  
  13. Connect the shift linkage using a new cotter pin.
  14.  
  15. Coat the cross shaft joint with grease and then install the shaft to the body. Connect the 2 transfer case linkages to the cross shaft.
  16.  
  17. Connect the oil cooler lines to the transmission case and install the bracket.
  18.  
  19. Connect the exhaust pipe to the tailpipe. Tighten the connecting nuts and pipe clamp bolt to 32 ft. lbs. (43 Nm).
  20.  
  21. Install the front and rear driveshafts.
  22.  
  23. Engage the five connectors under the air intake chamber.
  24.  
  25. Install the upper starter mounting nut.
  26.  
  27. Connect and adjust the throttle cable.
  28.  
  29. Connect the air intake connector and the negative battery cable. Fill the transmission with fluid and road test the truck. Check for any leaks.
  30.  

Tacoma
A340E AND A340F
  1. Remove the fluid level dipstick.
  2.  
  3. Remove the engine under cover.
  4.  
  5. Disconnect the throttle cable by loosening the nut then disconnecting the cable. Separate the cable from the clamp.
  6.  
  7. Remove the fan shroud.
  8.  
  9. Remove the transmission shift lever assembly and transfer case shift lever as follows:
    1. Remove the rear console box.
    2.  
    3. Remove the screws and the front console box with the transfer case shift lever knob.
    4.  
    5. Disconnect the harness wires.
    6.  
    7. Remove the nut and washer, then disconnect the shift control knob.
    8.  
    9. Unattach the harness then remove the 8 screws and transmission shift lever assembly.
    10.  
    11. Using snapring pliers, remove the snapring and pull out the shift lever from the transfer case.
    12.  
    13. When reinstalling, apply multi-purpose grease to the shift lever.
    14.  

  10.  
  11. Remove the fluid level pipe.
  12.  
  13. Remove the front and rear driveshafts.
  14.  
  15. Disconnect the front exhaust pipe.
  16.  
  17. Disconnect the following:

    Speedometer cable
     
    No. 2 vehicle speed sensor harness
     
    Solenoid harness
     
    Transfer case neutral position switch harness
     
    Transfer case L4 position switch harness
     
    Transfer case indicator switch
     

  18.  
  19. Remove the bolts and clamps holding the oil cooler pipe.
  20.  
  21. Loosen the union nuts and disconnect the oil cooler pipes.
  22.  
  23. Disconnect the temperature sensor harness.
  24.  
  25. Disconnect the neutral safety switch harness.
  26.  
  27. Remove the starter.
  28.  
  29. Unbolt the stabilizer bar bracket.
  30.  
  31. Remove the torque converter clutch mounting bolt:
    1. On the 3RZ-FE engine, remove the 2 nuts and bolts, then the 2 bolts and flywheel housing under cover.
    2.  
    3. On the 5VZ-FE engine remove the 4 bolts and flywheel housing under cover.
    4.  
    5. While turning the crankshaft to gain access, remove the 6 bolts. When installing first attach the green colored bolt then the other 5.
    6.  

  32.  
  33. Remove the front differential rear mounting cushion as follows:
    1. Using a hexagon wrench (12mm), remove the nut. then lift up the front differential.
    2.  
    3. Be careful not to touch the torque converter clutch housing and front differential companion flange.
    4.  
    5. Remove the 2 rear mounting cushion mounting bolts.
    6.  

  34.  
  35. Remove the crossmember, support the transmission rear side with a suitable jack.
  36.  
  37. Remove the mounting bolts then the crossmember. Be sure to support the transmission with a jack.
  38.  
  39. Lower the transmission rear side.
  40.  
  41. Separate the wire harness from the transmission.
  42.  
  43. On the 3RZ-FE engine remove the 4 bolts and transmission. On the 5VZ-FE engine, remove the 6 bolts and transmission.
  44.  
  45. To install reverse the procedure. Always use new gaskets and O-rings.
  46.  
  47. Fill the unit with the correct fluid, start the vehicle and test the operation.
  48.  

T100
A340E AND A340F
  1. Remove the fluid level dipstick.
  2.  
  3. Unbolt the engine under cover.
  4.  
  5. Disconnect the throttle cable by loosening the nut then disconnecting the cable. Separate the cable from the clamp.
  6.  
  7. Raise and safely support the vehicle.
  8.  
  9. Remove the fluid level dipstick.
  10.  
  11. Remove the front and rear driveshafts.
  12.  
  13. Disconnect the front exhaust pipe.
  14.  
  15. Disconnect the speedometer cable and vehicle speed sensor harness.
  16.  
  17. Remove the cross shaft as follows:
    1. Remove the clip and disconnect the No. 2 gear shifting rod.
    2.  
    3. Remove the nut, washer, 4 bolts and the cross shaft.
    4.  

  18.  
  19. Remove the oil cooler pipe.
  20.  
  21. Remove the bolts and clamps holding the oil cooler pipe.
  22.  
  23. Loosen the union nuts and disconnect the oil cooler pipes.
  24.  
  25. Disconnect the transmission fluid temperature sensor harness.
  26.  
  27. Disconnect the neutral safety switch harness.
  28.  
  29. Disconnect the starter wire.
  30.  
  31. Remove the stabilizer bar.
  32.  
  33. Remove the rear end plate nuts, bolts and plate.
  34.  
  35. Disconnect the rear mounting insulator.
  36.  
  37. Jack up the transmission.
  38.  
  39. While turning the crankshaft to gain access to the 6 bolts, remove them.
  40.  
  41. Disconnect the harness and connectors from the transmission.
  42.  
  43. Unbolt the transmission from the engine.
  44.  
  45. To install reverse the procedure. Always use new gaskets and O-rings.
  46.  
  47. Fill the unit with the correct fluid, start the vehicle and test the operation.
  48.  

Land Cruiser
A440F

See Figures 6 and 7

  1. Disconnect the negative battery cable.
  2.  
  3. Remove the battery and the battery cover.
  4.  
  5. Loosen the cooling fan shroud bolts. This will avoid fan damage.
  6.  



Click image to see an enlarged view

Fig. Fig. 6: Exploded view of the A440F transmission and components to be removed



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Fig. Fig. 7: Exploded view of the A440F transmission and components to be removed (continued)

  1. Loosen the adjusting nuts for the throttle control cable. Disconnect the cable housing from the bracket; disconnect the cable from the throttle linkage.
  2.  
  3. Unplug the electrical connectors near the starter.
  4.  
  5. Remove the transfer case shift lever as follows:
    1. Under the vehicle, remove the nut and transmission control rod.
    2.  
    3. Remove the transfer case shift lever knob.
    4.  
    5. Remove the four screws holding the console and remove the console.
    6.  
    7. Remove the four bolts and remove the transfer case shift lever boot.
    8.  
    9. Remove the three bolts holding the console box.
    10.  
    11. Remove the six bolts holding the transmission shift lever assembly. Remove the assembly.
    12.  
    13. Pull out the pin and disconnect the shift rod.
    14.  
    15. Remove the four bolts holding the transfer case shift lever and remove the lever assembly.
    16.  

  6.  
  7. Elevate and safely support the vehicle. Double check the supports for placement and security.
  8.  
  9. Disconnect the speedometer cable.
  10.  
  11. Remove the front and rear propeller shafts.
  12.  
  13. Remove the starter.
  14.  
  15. Remove the two line clamps and disconnect the oil cooler lines at the transmission.
  16.  
  17. Remove the undercover.
  18.  
  19. Remove the endplate hole plug. Turn the crankshaft to gain access to each of the six torque converter mounting bolts. Remove the bolts.
  20.  
  21. Support the transmission, either with a transmission jack (preferred) or a floor jack and a broad piece of wood to protect the transmission. Tension the jack just enough to take tension off the crossmember.
  22.  
  23. Remove the bolts and nuts holding the crossmember and remove it.
  24.  
  25. Use a floor jack and a piece of wood to support the engine under the oil pan. Do NOT bend the oil pan.
  26.  
  27. Lower the rear end of the transmission and slide the unit away from the engine.
  28.  
  29. With the transmission removed, set up a dial indicator and measure the driveplate run-out. If run-out exceeds 0.0079 in. (0.20mm) or if the ring gear is damaged, the driveplate must be replaced.
  30.  
  31. Temporarily mount the torque converter to the driveplate. Set up a dial indicator and measure run-out at the center of the torque converter. If run-out exceeds 0.0118 in. (0.30mm), try to correct it by repositioning the torque converter. If the repositioning corrects the error, make matchmarks so that the position is used at reinstallation. If the misalignment cannot be corrected, the torque converter must be replaced. Remove the torque converter when measurement is completed.
  32.  

To install:
  1. With the torque converter installed on the transmission, check the converter installation with a straightedge across the front of the case. Correct distance from the surface of the bolt lugs to the front of the case is 0.618 in. (1.57mm) or more. If the distance measured is less than specified, check the converter for improper installation.
  2.  
  3. Elevate the transmission and push it fully into place. Install the transmission retaining bolts and tighten them to 53 ft. lbs. (72 Nm).
  4.  
  5. Install the rear mount to the transmission. Tighten the retaining bolts to 43 ft. lbs. (59 Nm).
  6.  
  7. Install the crossmember. Tighten the bolts to 45 ft. lbs. (61 Nm) and the nuts to 43 ft. lbs. (59 Nm).
  8.  
  9. Install the torque converter mounting bolts, tightening them to 21 ft. lbs. (28 Nm). Install the end plate hole plug when finished.
  10.  
  11. Install the undercover.
  12.  
  13. Connect the oil cooler lines, tightening the fittings to 25 ft. lbs. (34 Nm). Install the cooler line clamps.
  14.  
  15. Install the front and rear driveshafts.
  16.  
  17. Install the oil filler tube.
  18.  
  19. Install the starter.
  20.  
  21. Connect the speedometer cable.
  22.  
  23. The transfer case shift lever is installed by reversing the removal sequence. The four shift lever bolts should be tightened to 13 ft. lbs. (18 Nm). The six bolts holding the transmission shift lever should be tightened only to 48 inch lbs. (5 Nm).
  24.  
  25. Engage the electrical connectors near the starter.
  26.  
  27. Connect and adjust the throttle cable.
  28.  
  29. Tighten the fan shroud bolts.
  30.  
  31. Connect the negative battery cable.
  32.  
  33. Add the correct amount of fluid.
  34.  

A343F AND A442F

See Figures 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, 20, 21, 22, 23, 24, 25, 26 and 27

  1. Remove the battery and battery tray. Always disconnect the negative battery cable first.
  2.  
  3. Unbolt the fan shroud for the cooling fan.
  4.  



Click image to see an enlarged view

Fig. Fig. 8: Unbolt the fan shroud for the cooling fan

  1. Disconnect the throttle cable by loosening the adjusting nut and removing the cable from the bracket.
  2.  



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Fig. Fig. 9: Disconnect the throttle cable by loosening the adjusting nut

  1. Detach the cable from the linkage.
  2.  
  3. Remove the upper side starter mounting bolt.
  4.  



Click image to see an enlarged view

Fig. Fig. 10: The upper side starter mounting bolt is located at the arrow

  1. Remove the clip, washer and wave washer, then disconnect the transfer case shift lever link.
  2.  



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Fig. Fig. 11: When removing the select lever and shift lever, always discard the old clip; it should not be reused

  1. Remove the nut and washer, then disconnect the transmission select lever link.
  2.  



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Fig. Fig. 12: Use the correct size wrench to remove this nut, as a rounded-off nut is never pleasant

  1. Unscrew the transfer case shift lever knob.
  2.  



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Fig. Fig. 13: After removing the shift knob, unscrew the console

  1. Unbolt the console and set aside.
  2.  



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Fig. Fig. 14: The shift lever boot has 4 mounting screws

  1. Remove the mounting screws for the transfer case shift lever boot.
  2.  
  3. Remove the console box.
  4.  



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Fig. Fig. 15: The other console screws are on the top and deep inside

  1. Disconnect the wiring harnesses.
  2.  



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Fig. Fig. 16: Disconnect the harnesses, then move them out of the way. If necessary, tag them to simplify reconnection

  1. Remove the 6 mounting screws for the transmission shift lever assembly.
  2.  



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Fig. Fig. 17: These six screws surround the shift lever assembly

  1. Unbolt the transfer case shift lever, then remove the two cushions.
  2.  



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Fig. Fig. 18: Once these four bolts are removed, separate the two cushions underneath

  1. If applicable, disconnect the following:

    Vehicle speed sensors
     
    Neutral safety switch
     
    Solenoid connector
     
    ATF temperature sensor
     
    Center differential lock indicator switch
     
    L4 position switch
     
    Bleeder hose from the transfer case
     

  2.  
  3. Remove the front and rear driveshafts.
  4.  
  5. Remove the oil level dipstick.
  6.  



Click image to see an enlarged view

Fig. Fig. 19: There is a side mounting bolt for the oil filler tube

  1. Unbolt the upper side mounting.
  2.  
  3. Remove the bolt retaining the filler pipe. Discard the old O-ring.
  4.  
  5. Loosen the two oil cooler pipe union nuts.
  6.  



Click image to see an enlarged view

Fig. Fig. 20: A pipe wrench may be used to separate the union nuts on the oil cooler line

  1. Remove the 4 stabilizer bar bracket mounting bolts.
  2.  



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Fig. Fig. 21: When removing the stabilizer bar bolts, there are two U-brackets holding the bar into place

  1. Separate the engine undercover from the vehicle.
  2.  



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Fig. Fig. 22: The engine under cover is located above the center link

  1. Take the converter plug off.
  2.  
  3. Turn the crankshaft to gain access to each bolt, then hold the crankshaft pulley nut with a wrench and remove the 6 bolts.
  4.  
  5. Remove the front exhaust pipe, discard the gaskets.
  6.  
  7. Remove the starter.
  8.  
  9. Support the transmission with a suitable jack. Remove the bolts and nuts retaining the crossmember. Lower the crossmember.
  10.  



Click image to see an enlarged view

Fig. Fig. 23: You will need an extension to remove the bolts on the crossmember

  1. Lower the rear end of the transmission. Be careful not to damage the cooling fan, brake booster and brake line.
  2.  
  3. Separate the wire harness from the transmission and transfer case.
  4.  



Click image to see an enlarged view

Fig. Fig. 24: Exploded view of components to be removed-A343F transmission

  1. Remove the cooler pipe mounting bolts from the torque converter clutch housing, then disconnect the 2 oil cooler pipes from the elbows.
  2.  
  3. Remove the transmission mounting bolts.
  4.  

To install:


Click image to see an enlarged view

Fig. Fig. 25: Exploded view of the A343F transmission and components to be removed (continued)

  1. Using calipers and a straightedge, measure from the installed surface of the transmission housing. The distance should be more than 0.618 in. (15.7mm). Install the transmission, tighten to 53 ft. lbs. (72 Nm).
  2.  
  3. Attach the oil cooler pipe mounting with the bolts to the converter housing, then attach the harness to the transfer case and transmission.
  4.  
  5. Attach the crossmember to the vehicle. Tighten the 8 bolts to 45 ft. lbs. (61 Nm) and the 2 nuts to 54 ft. lbs. (74 Nm).
  6.  



Click image to see an enlarged view

Fig. Fig. 26: Exploded view of components to be removed-A442F transmission

  1. Install the starter. Tighten the bolts to 29 ft. lbs. (39 Nm). Attach the harness.
  2.  
  3. Using new gaskets and nuts, attach the front exhaust pipe. Tighten the support bracket to 17 ft. lbs. (24 Nm), the clamp bolts to 14 ft. lbs. (19 Nm), the front pipe-to-manifold 46 ft. lbs. (62 Nm), and the front pipe-to-catalytic converter to 29 ft. lbs. (39 Nm).
  4.  
  5. Install the torque converter clutch mounting bolt. Tighten to 40 ft. lbs. (55 Nm). First install the gray colored bolt, then the other 5 bolts.
  6.  



Click image to see an enlarged view

Fig. Fig. 27: Exploded view of the A442F transmission and components to be removed (continued)

  1. Install the front engine undercover, tighten to 21 ft. lbs. (28 Nm).
  2.  
  3. Place the 4 stabilizer bar bracket mounting bolts into position, then tighten to 13 ft. lbs. (18 Nm).
  4.  
  5. Attach the 2 oil cooler pipe union nuts.
  6.  
  7. With a new O-ring, install the oil filler pipe. Insert the level dipstick into the pipe.
  8.  
  9. Install the front and rear driveshafts.
  10.  
  11. Install the following:

    Center differential lock indicator switch
     
    L4 position switch
     
    Neutral safety switch and connector
     
    Bleeder hose from the transfer case
     
    Vehicle speed sensors
     
    Solenoid connector
     
    ATF temperature sensor
     

  12.  
  13. Place the transfer case shift lever into position. Tighten the 4 bolts to 13 ft. lbs. (18 Nm). Attach the 6 screws, tighten to 48 inch lbs. (5 Nm).
  14.  
  15. Attach the connectors to the shift lever assembly. Install the 3 mounting bolts on the console box. Place the shift lever boot into position, then tighten the 4 screws. Slip the console over the lever assembly and tighten the 4 screws.
  16.  
  17. Screw on the transfer case shifter knob.
  18.  
  19. Place the nut and washer on the select lever linkage.
  20.  
  21. Install the wave washer, washer and new clip onto the shift lever linkage.
  22.  
  23. Attach the upper side starter mounting bolt. Tighten to 29 ft. lbs. (39 Nm).
  24.  
  25. Attach the throttle linkage.
  26.  
  27. Install the fan shroud for the cooling fan.
  28.  
  29. Install the battery tray and battery.
  30.  
  31. Fill the transmission.
  32.  
  33. Start the vehicle. Test the operation of the unit.
  34.  

 
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