Automatic Transmission Removal & Installation: Application Toyota 4Runner IV

APPLICATION

TRANSMISSION APPLICATION

Note. To assist in removal and installation of transmission (Scheme 189)

1. Remove ATF level gauge. Remove oil filler pipe. Remove the bolt and oil filler pipe with "O" ring. (Scheme 190)
2. Remove 2 engine under covers.
3. Place matchmarks on drive shaft flange and mating flange. Unbolt and remove drive shaft.
4. Remove front exhaust pipe.
5. Disconnect transmission control rod from shift lever. (Scheme 191)
6. Disconnect no. 2 vehicle speed sensor connector from transmission.
7. Disconnect solenoid wire connector from transmission.
8. Disconnect ATF temperature sensor connector from transmission.
9. Disconnect park/neutral position switch connector from transmission.
10. Separate wire harness from transmission.
11. Disconnect oil cooler pipe. Remove the 3 bolts and oil cooler pipe clamps. (Scheme 192) Disconnect the 2 oil cooler pipes. (Scheme 193)
12. Remove rear end plate and torque converter clutch mounting bolt. Remove the 4 bolts and rear end plate. (Scheme 194) Turn the crankshaft to gain access and remove the 6 bolts with holding the crankshaft pully set bolt by a wrench.
13. Jack up transmission slightly using a transmission jack. Support the transmission.
14. Remove No. 3 crossmember. Remove the 4 set bolts of the engine rear mounting. Remove the 4 bolts, nuts and No. 3 crossmember. (Scheme 195)
15. Remove engine rear mounting. Remove the 4 bolts and engine rear mounting from the transmission.
16. Remove starter. Remove the nut and disconnect the starter wire and connector. Remove the 2 bolts and starter.
17. Remove transmission. Remove the 6 bolts and transmission. (Scheme 196)

Scheme 189

Scheme 190

Scheme 191

Scheme 192

Scheme 193

Scheme 194

Scheme 195

1. Before installing transaxle, use dial indicator to check drive plate runout. Drive plate runout should be checked near starter ring gear on drive plate. Replace drive plate if runout exceeds.008" (.20 mm).
2. Using straightedge and caliper, measure torque converter depth from torque converter bolt lug on torque converter to the surface on transaxle. (Scheme 197)
3. Torque converter depth should be more than.707" (17.95 mm). If torque converter depth is less than specified, check for improperly seated torque converter.
4. To install, reverse removal procedure. Tighten all fasteners to specification. See TORQUE SPECIFICATIONS. Adjust all cables and fill transaxle with fluid. See appropriate SERVICING article.

Scheme 196

Note. To assist in removal and installation of transmission (Scheme 198)

1. Remove ATF level gauge.
2. Remove oil filler pipe. Remove the bolt and oil filler pipe with "O" ring.
3. Remove transmission shift lever assembly and transfer shift lever. Remove the screw and disconnect the transfer shift lever knob. Remove the front console upper panel. Disconnect the 2-4 selector connector and remove the transfer shift lever knob. Remove the 2 clips, screws and front console box. (Scheme 199)
4. Remove the nut and washer and disconnect the shift control rod. (Scheme 200) Disconnect the connector and remove the 8 bolts and transmission shift lever assembly. (Scheme 201) Using pliers, remove the snap ring and pull out the transfer shift lever from the transfer. (Scheme 202)
5. Remove 2 engine under covers.
6. Place matchmarks on drive shaft flange and mating flange. Unbolt and remove front and rear drive shafts.
7. Remove front exhaust pipe.
8. Disconnect No. 2 vehicle speed sensor connector from transmission.
9. Disconnect solenoid connector from transmission.
10. Disconnect ATF temperature sensor connector from transmission.
11. Disconnect park/neutral position switch connector from transmission.
12. Disconnect No. 1 vehicle speed sensor connector from transfer.
13. Disconnect transfer neutral position switch connector from transfer case.
14. Disconnect transfer L4 position switch connector from transfer case.
15. Disconnect transfer 4WD position switch connector from transfer case.
16. Disconnect actuator connector from transfer case.
17. Separate wire harness from transmission and transfer case.
18. Disconnect oil cooler pipe. Remove the 3 bolts and oil cooler pipe clamps. (Scheme 192) Disconnect the 2 oil cooler pipes. (Scheme 193)
19. Remove rear end plate and torque converter clutch mounting bolt. Remove the 4 bolts and rear end plate. (Scheme 194) Turn the crankshaft to gain access and remove the 6 bolts with holding the crankshaft pulley set bolt by a wrench.
20. Remove No. 3 crossmember. Support the transmission rear side with a support stand. Remove the 4 set bolts of the engine rear mounting. Remove the 4 bolts, nuts and No. 3 crossmember. (Scheme 195)
21. Remove engine rear mounting. Remove the 4 bolts and engine rear mounting from the transmission.
22. Remove No. 4 crossmember. Remove the 4 bolts, nuts and No. 4 crossmember. (Scheme 203)
23. Jack up transmission. Support the transmission with a transmission jack. (Scheme 204) Remove a support stand from the transmission rear side.
24. Remove starter. Remove the nut and disconnect the starter wire and connector. Remove the 2 bolts and starter.
25. Remove transmission. Disconnect the stabilizer bar. Remove the 6 bolts and transmission. (Scheme 196)

Scheme 197

Scheme 198

Scheme 199

Scheme 200

Scheme 201

Scheme 202

1. Before installing transaxle, use dial indicator to check drive plate runout. Drive plate runout should be checked near starter ring gear on drive plate. Replace drive plate if runout exceeds.008" (.20 mm).
2. Using straightedge and caliper, measure torque converter depth from torque converter bolt lug on torque converter to the surface on transaxle. (Scheme 197)
3. Torque converter depth should be more than.707" (17.95 mm). If torque converter depth is less than specified, check for improperly seated torque converter.
4. To install, reverse removal procedure. Tighten all fasteners to specification. See «TORQUE SPECIFICATIONS»(ref-158065-S32177634182003090900000). Adjust all cables and fill transaxle with fluid. See appropriate SERVICING article.

Note. To assist in removal and installation of transmission (Scheme 205)and (Scheme 206).

1. Remove engine under cover sub-assembly No. 1.
2. Remove engine under cover assembly rear.
3. Disconnect oxygen sensor.
4. Remove exhaust pipe.
5. Place matchmarks on drive shaft flange and mating flange. Unbolt and remove front (if applicable) and rear drive shafts.
6. Drain automatic transmission fluid. Remove the drain plug, gasket and drain ATF. Install a new gasket and drain plug.
7. Remove front suspension member bracket. Remove the 4 bolts and front suspension member bracket. (Scheme 207)
8. Remove front suspension member bracket LH. Remove the 4 bolts and front suspension member bracket LH.
9. Remove transmission oil filler tube sub-assembly. Remove the ATF level gauge. Remove the bolt and oil filler tube. Remove the "O" ring from the oil filler tube.
10. Disconnect oil cooler outlet tube No. 1. Remove the 2 bolts and 2 clamps. (Scheme 208) Disconnect the oil cooler outlet tube No. 1. (Scheme 209)
11. Remove oil cooler inlet tube No. 1. Disconnect the oil cooler inlet tube No. 1.
12. Disconnect transmission control cable assembly. Remove the nut and disconnect the transmission control cable. Remove the lock plate and disconnect the transmission control cable. (Scheme 210)
13. Remove transmission control cable bracket No. 1. Remove the 2 bolts and transmission control cable bracket.
14. Support automatic transmission assembly.
15. Remove frame crossmember sub-assembly No. 3. Remove the 4 bolts on the frame crossmember sub-assembly No. 3. Remove the 4 nuts, 4 bolts and frame crossmember sub-assembly No. 3. (Scheme 195)
16. Disconnect connector. Tilt down the transmission. (Scheme 204) Take care so that the cooling fan does not come in contact with the fan shroud. Disconnect the park/neutral position switch connector. Disconnect the transmission wire connector. Disconnect the 2 speed sensor connectors.
17. Disconnect wire harness.
18. Remove flywheel housing under cover. Remove the 2 bolts and flywheel housing under cover.
19. Remove transmission assembly. Turn the crankshaft to gain access to each bolt. Hold the crankshaft pulley nut with a wrench and remove the 6 bolts. Remove the 10 bolts. Separate and remove the automatic transmission.
20. Remove engine mounting insulator rear No. 1. Remove the 4 bolts and rear engine mounting insulator from the automatic transmission. see scheme 23
21. Remove torque converter clutch assembly.
22. Inspect torque converter clutch assembly.

Scheme 203

Scheme 204

Scheme 205

Scheme 206

Scheme 207

1. Install the torque converter clutch to the transaxle. Using vernier calipers, measure the dimension "A" the transaxle fitting part and the converter fitting part of the drive plate. see scheme 24
2. Using vernier calipers and a straight edge, measure the dimension "B" and check that "B" is greater than dimension "A". see scheme 25 Standard: "A" + 1 mm or more. Do not add the thickness of straight edge.
3. Install engine mounting insulator rear No. 1. Install the engine mounting insulator rear and 4 bolts to the automatic transmission. see scheme 23
4. Install transmission assembly. Install the automatic transmission and 10 bolts to the engine. see scheme 26 Install the 6 torque converter clutch mounting bolts.
5. Install the flywheel housing under cover and 2 bolts.
6. Install wire harness.
7. Install frame crossmember sub-assembly No. 3. Install the frame crossmember sub-assembly No. 3 with 4 bolts and 4 nuts. Install the frame crossmember sub-assembly No. 3 with 4 bolts. (Scheme 195)
8. Install transmission control cable bracket No. 1. Install the transmission control cable bracket No. 1 with 2 bolts. (Scheme 210)
9. Connect transmission control cable assembly. Connect the transmission control cable with lock plate. Connect the transmission control cable with nut.
10. Install oil cooler outlet tube No. 1. Temporarily install the oil cooler outlet tube No. 1. Temporarily install the oil cooler inlet tube No. 1. Install the 2 clamps and 2 bolts. (Scheme 208) Tighten the oil cooler outlet tube No. 1. (Scheme 209)
11. Install oil cooler inlet tube No. 1. Tighten the oil cooler inlet tube No. 1.
12. Install transmission oil filler tube sub-assembly. Coat a new "O" ring with ATF, and install them to the oil filler tube. Install the oil filler tube and bolt to the automatic transmission. Install the ATF level gauge.
13. Install front suspension member bracket LH. Install the front suspension member bracket LH with 4 bolts. (Scheme 207)
14. Install front suspension member bracket. Install the front suspension member bracket with 4 bolts.
15. Install drive shaft assemblies.
16. Adjust shift lever position. See appropriate SERVICING article.
17. Install exhaust pipe.
18. Install oxygen sensor.
19. Install engine under cover sub-assembly No. 1.
20. Install engine under cover assembly rear.
21. Add automatic transmission fluid. See appropriate SERVICING article.

Scheme 208

Scheme 209

Scheme 210