Toyota Previa 1991-1997 Repair Information

Automatic Transmission Assembly

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REMOVAL & INSTALLATION



See Figure 1



Click image to see an enlarged view

Fig. Fig. 1: Exploded view of the automatic transmission mounting

4-Speed Transmissions
  1. Disconnect the negative battery terminal from the battery. Wait at least 90 seconds after the battery cable is disconnected before working on the vehicle if equipped with air bags.
  2.  
  3. If required, remove the air cleaner assembly.
  4.  
  5. Disconnect the transmission throttle cable from the throttle body.
  6.  
  7. Raise and safely support the vehicle.
  8.  
  9. Drain the transmission fluid.
  10.  
  11. Disconnect the wiring harness for the neutral start switch and the back-up light switch. If equipped, disconnect the solenoid (overdrive) switch wiring at the same location.
  12.  
  13. If equipped, disconnect the oil level gauge.
  14.  
  15. Disconnect the starter wiring at the starter. Remove the mounting bolts and the starter from the engine.
  16.  
  17. Make matchmarks on the rear driveshaft flange and the differential pinion flange. These marks must be aligned during installation.
  18.  
  19. Unbolt the rear driveshaft flange. If the vehicle has a 2 piece driveshaft, remove the center bearing bracket-to-frame bolts. Remove the driveshaft from the vehicle.
  20.  
  21. Disconnect the speedometer cable (tie it aside). Disconnect the shift linkage from the transmission.
  22.  
  23. Disconnect the transmission oil cooler lines at the transmission.
  24.  
  25. Disconnect the exhaust pipe clamp and remove the oil filler tube, as required.
  26.  
  27. Support the transmission, using a jack with a wooden block placed between the jack and the transmission pan. Raise the transmission, just enough to take the weight off of the rear mount.
  28.  
  29. Remove the rear engine mount with the bracket and the engine under cover, to gain access to the engine crankshaft pulley.
  30.  
  31. Remove the stiffener plates, if equipped.
  32.  
  33. Place a wooden block (or blocks) between the engine oil pan and the front frame crossmember.
  34.  
  35. Slowly, lower the transmission until the engine rests on the wooden block.
  36.  
  37. Remove the rubber plug(s) from the service holes located at the rear of the engine in order to gain access to the torque converter bolts.
  38.  
  39. Rotate the crankshaft (to remove the torque converter bolts) to access the bolts through the service holes.
  40.  
  41. Obtain a bolt of the same dimensions as the torque converter bolts. Cut the head off of the bolt and hacksaw a slot in the bolt opposite the threaded end.
  42.  

This modified bolt is used as a guide pin. Two guides 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 stiffener plates from the transmission.
  4.  
  5. Remove the transmission-to-engine bolts, then carefully move the transmission rearward by prying on the guide pin through the service hole.
  6.  
  7. Pull the transmission rearward and lower it (front end down) out of the vehicle.
  8.  

To install:
  1. Installation is the reverse of removal. Please note the following important steps.
  2.  
  3. Apply a coat of Multi-purpose grease to the torque converter stub shaft and the corresponding pilot hole in the flexplate.
  4.  
  5. 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.
  6.  
  7. To make sure 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 1991-95 models: 1.250 inch (31.75mm) and on 1996-97 models: 0.079 inch (20mm).
  8.  
  9. Install guide pins into 2 opposite mounting lugs of the torque converter.
  10.  
  11. Raise the transmission to the engine, align the transmission with the engine alignment dowels and position the converter guide pins into the mounting holes of the flexplate.
  12.  
  13. Install and tighten the transmission-to-engine mounting bolts. Tighten the bolts to specifications.
  14.  
  15. 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. Evenly, tighten the converter mounting bolts to specifications. Install the rubber plugs into the access holes.
  16.  
  17. Install the remaining components by reversing the removal procedure.
  18.  
  19. Adjust the transmission throttle cable.
  20.  
  21. Refill the transmission.
  22.  
  23. Connect the negative battery cable. Start the engine and check for leaks.
  24.  
  25. Road test the vehicle for proper operation.
  26.  
  27. Recheck all fluid levels.
  28.  

3-Speed Transmissions
  1. Disconnect the negative battery terminal from the battery. Wait at least 90 seconds after the battery cable is disconnected before working on the vehicle if equipped with air bags.
  2.  
  3. Remove the ATF level gauge.
  4.  
  5. Loosen the nut and disconnect the throttle cable.
  6.  
  7. Remove the equipment driveshaft.
  8.  
  9. Raise and safely support the vehicle.
  10.  
  11. Remove the filler pipe. Remove the driveshaft.
  12.  
  13. Disconnect the control cable.
  14.  
  15. Disconnect the No. 1 and No. 2 vehicle speed sensor harnesses. Disconnect the starter solenoid wiring.
  16.  
  17. Disengage the neutral safety switch harness.
  18.  
  19. Remove the bolt and disconnect the oil pipe clamp. Disconnect the oil cooler pipes. On 4WD disconnect the A/T fluid temperature switch harness.
  20.  
  21. Remove the starter.
  22.  
  23. Using a jack, support the transmission. Remove the stiffener plate.
  24.  
  25. Remove the torque converter clutch cover and turn the crankshaft to gain access and remove the six bolts.
  26.  
  27. Remove the exhaust pipe bracket. Remove the rear mounting bolts.
  28.  
  29. Remove the transmission mounting bolts, then detach the wire harness, and lower the transmission.
  30.  
  31. Installation is the reverse of removal. Please note the following important steps.
  32.  
  33. Connect wire harness and install the transmission. Tighten the bolts to specifications.
  34.  
  35. Install the remaining components and tighten to specifications. Install the equipment driveshaft.
  36.  
  37. Connect the throttle cable and tighten.
  38.  
  39. Install the ATF level gauge.
  40.  
  41. Check the shift lever position.
  42.  
  43. Check the fluid level and fill if necessary.
  44.  
  45. Connect the negative battery cable.
  46.  

ADJUSTMENTS



Throttle Linkage

See Figure 2

  1. Depress the accelerator pedal all the way and check that the throttle valve opens fully.
  2.  
  3. If the valve does not open fully, adjust the accelerator cable.
  4.  



Click image to see an enlarged view

Fig. Fig. 2: Measure the distance between the end of the boot and stopper on the throttle cable

  1. Fully depress the accelerator pedal.
  2.  
  3. Measure the distance between the end of the boot and stopper on the cable. Standard distance is 0-0.04 inch (0-1mm).
  4.  
  5. If the distance is not within specifications, adjust the cable by the adjusting nuts.
  6.  

 
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