Automatic Transmission Assembly: Installation

Attach the ST to converter case.
ST 498277200 STOPPER SET

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When completely overhauling the transmission, refill approx. 10 L (2.6 US qt, 8.8 Imp qt) of CVTF through the transmission right side plug, and install the plug.
CAUTION: Always use specified CVTF. Using other fluid will cause malfunction. Ref. to CONTINUOUSLY VARIABLE TRANSMISSION (TR690)>General Description>SPECIFICATION>HYDRAULIC CONTROL AND LUBRICATION .

NOTE: Use a new gasket.

Tightening torque:

35 N.m (3.6 kgf-m, 25.8 ft-lb)

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Replace the front differential side retainer oil seal. Ref. to CONTINUOUSLY VARIABLE TRANSMISSION (TR690)>Differential Side Retainer Oil Seal>REPLACEMENT .
NOTE:
- Be sure to replace the differential side retainer oil seal with a new part whenever the front drive shaft is removed from the transmission.
- When a new differential side retainer oil seal has been installed, replacement is not required.
Install the rear cushion rubber.
Tightening torque:

40 N.m (4.1 kgf-m, 29.5 ft-lb)

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Mount the transmission onto the transmission jack.
Strike and bend the transmission hanger of transmission rear with a rubber hammer etc. so that it gets in contact with the transmission case.
CAUTION: Do not apply extra overload or impact to the transmission case.

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Remove the pitching stopper bracket, if mounted.
Install the transmission onto the engine.
NOTE:
- While raising the transmission jack gradually, turn the screw of engine support, then tilt the engine forward.
- Temporarily attach the two engine connecting bolts and two nuts (lower side).
Install the transmission rear crossmember.
Tightening torque:

T1: 35 N.m (3.6 kgf-m, 25.8 ft-lb)

T2: 70 N.m (7.1 kgf-m, 51.6 ft-lb)

Fig 1: Transmission Rear Crossmember Bolts (With Torque Specification)
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Tighten the two engine connecting bolts and two nuts (lower side).
Tightening torque:

50 N.m (5.1 kgf-m, 36.9 ft-lb)

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Remove the transmission jack.
Lower the vehicle.
Install the three engine mounting bolts (upper side).
Tightening torque:

50 N.m (5.1 kgf-m, 36.9 ft-lb)

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Remove the ST (STOPPER SET) from converter case.
Remove the ST (ENGINE SUPPORT ASSY).
ST 41099AC000 ENGINE SUPPORT ASSY

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Match the torque converter screw hole with drive plate hole to install the bolt.
CAUTION:
- Do not drop the mounting bolt in the converter housing.
- Do not damage the mounting bolt.
Tightening torque:

25 N.m (2.5 kgf-m, 18.4 ft-lb)
Install the remaining three bolts by rotating the crank pulley a little at a time in the same direction as engine revolution.
Tightening torque:

25 N.m (2.5 kgf-m, 18.4 ft-lb)
Install the service hole plug.

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Install the engine ground terminals.
Tightening torque:

19 N.m (1.9 kgf-m, 14.0 ft-lb)

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Install the pitching stopper bracket and transmission radio ground cord.
CAUTION: Be careful not to deform or damage the terminal of transmission radio ground cord.

Tightening torque:

41 N.m (4.2 kgf-m, 30.2 ft-lb)

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Install the CVTF cooler pipe COMPL.
Tightening torque:

16 N.m (1.6 kgf-m, 11.8 ft-lb)

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Install the starter. Ref. to STARTING/CHARGING SYSTEMS (H4DOTC)>GENERAL DESCRIPTION .
Install the transmission harness stay.
Tightening torque:

16 N.m (1.6 kgf-m, 11.8 ft-lb)

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Install the pitching stopper.
Tightening torque:

T1: 50 N.m (5.1 kgf-m, 36.9 ft-lb)

T2: 58 N.m (5.9 kgf-m, 42.8 ft-lb)

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Lift up the vehicle.
Set the ST to differential side retainer.
ST 28399SA010 OIL SEAL PROTECTOR

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Replace the circlip of the drive shaft with a new part.
Insert the front drive shaft spline section into transmission and remove the ST (OIL SEAL PROTECTOR).
NOTE:
- Before inserting the front drive shaft RH, turn the steering wheel to the right hand at full lock.
- Before inserting the front drive shaft LH, turn the steering wheel to the left hand at full lock.
Insert the drive shaft into the transmission securely by pressing the housing from outside of the vehicle.
Insert the ball joint into housing and secure with bolt.
Tightening torque:

50 N.m (5.1 kgf-m, 36.9 ft-lb)
CAUTION:
- Do not apply grease to the tapered portion of ball stud.
- Before tightening, make sure the lower side of housing and stepped section of ball joint are in contact.
Replace the flange nut with a new part, and install the stabilizer link.
Tightening torque:

60 N.m (6.1 kgf-m, 44.3 ft-lb)
Install the propeller shaft. Ref. to DRIVE SHAFT SYSTEM>Propeller Shaft>INSTALLATION .
Install the cable plate assembly.
Tightening torque:

T: 25 N.m (2.5 kgf-m, 18.4 ft-lb)

Fig 2: Cable Plate Assembly Bolts (With Torque Specification)
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Connect the select cable, and install the washer and snap pin.
CAUTION: Do not apply excessive load while holding the part (A).

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Connect the secondary pressure sensor harness connector.

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Install the exhaust hanger bracket.
Tightening torque:

23 N.m (2.3 kgf-m, 17.0 ft-lb)
Install the center exhaust cover.
Tightening torque:

18 N.m (1.8 kgf-m, 13.3 ft-lb)

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Install the center exhaust pipe. Ref. to EXHAUST (H4DOTC)>Center Exhaust Pipe>INSTALLATION .
Install the under cover.
Lower the vehicle.
Replace the CVTF inlet hose and CVTF outlet hose. Ref. to CONTINUOUSLY VARIABLE TRANSMISSION (TR690)>CVTF Cooler (With Warmer Function)>ASSEMBLY .
Install the CVTF cooler (with warmer feature).
Tightening torque:

23 N.m (2.3 kgf-m, 17.0 ft-lb)

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Connect the CVTF inlet hose and the outlet hose.

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Install the air breather hose to the pitching stopper bracket.
Connect the primary pressure sensor harness connector.

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Install the engine hanger rear.
Tightening torque:

21 N.m (2.1 kgf-m, 15.5 ft-lb)

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Install the harness clip.

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Connect the following harness connectors.
- Transmission harness connectors
- Transmission radio ground terminal
- Inhibitor harness connector
- Engine harness connectors
Tightening torque:

13 N.m (1.3 kgf-m, 9.6 ft-lb)

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Install the intercooler. Ref. to INTAKE (INDUCTION) (H4DOTC)>Intercooler>INSTALLATION .
Install the air intake duct. Ref. to INTAKE (INDUCTION) (H4DOTC)>Air Intake Duct>INSTALLATION .
Install the front tires.
Connect the battery ground terminal.
Refill differential gear oil to adjust the differential gear oil amount. Ref. to CONTINUOUSLY VARIABLE TRANSMISSION (TR690)>Differential Gear Oil>ADJUSTMENT .
Refill CVTF to adjust the CVTF amount. Ref. to CONTINUOUSLY VARIABLE TRANSMISSION (TR690)>CVTF>ADJUSTMENT .
Perform the variator chain break-in. Ref. to CONTINUOUSLY VARIABLE TRANSMISSION (TR690)>VARIATOR CHAIN BREAK-IN .
CAUTION: Always execute the variator chain break-in after the replacement of the following.
- Variator chain replacement
- Primary pulley and secondary pulley replacement
Perform the operation of AT learning mode. Ref. to TRANSMISSION (DIAGNOSTICS)>LEARNING CONTROL .
Execute the rear differential inspection mode. Ref. to DIFFERENTIALS>REAR DIFFERENTIAL INSPECTION MODE .
CAUTION: Always execute the rear differential inspection mode at the replacement of the following.
- Replacement of transmission assembly
- Replacement of front differential hypoid gear set
Perform the road test to make sure there is no fault. Ref. to CONTINUOUSLY VARIABLE TRANSMISSION (TR690)>Road Test>INSPECTION .