On-Vehicle Repair

REMOVE LH ENGINE UNDER COVER
REMOVE DRAIN PLUG AND DRAIN ATF
REMOVE OIL PAN AND GASKET
Remove the 19 bolts, oil pan and gasket.

NOTE: Some fluid will remain in the oil pan. Remove all pan bolts, and carefully remove the oil pan assembly. Discard the gasket.

Fig 1: Removing Oil Pan
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE 2 MAGNETS FROM OIL PAN

Fig 2: Removing Magnets From Oil Pan
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
EXAMINE PARTICLES IN PAN
Remove the magnets and use them to collect any steel chips. Look carefully at the chips and particles in the pan and the magnet to anticipate what type of wear you will find in the transaxle. Steel (magnetic): bearing, gear and plate wear

Brass (non-magnetic): bearing wear

Fig 3: Collecting Steel Chips From Magnets
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE OIL STRAINER
NOTE: Be careful as some fluid will come out with the oil strainer.
1. Remove the 3 bolts and oil strainer.
  
  Fig 4: Removing Oil Strainer
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Remove the O-ring from the oil strainer.
  
  Fig 5: Removing O-Ring From Oil Strainer
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
DISCONNECT 5 SHIFT SOLENOID VALVE CONNECTORS
DISCONNECT ATF TEMPERATURE SENSOR
Remove the bolt and lock plate, and remove the ATF temperature sensor.

Fig 6: Removing ATF Temperature Sensor
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE VALVE BODY
1. Remove the 2 bolts, cover and detent spring.
2. Remove the 12 bolts and valve body.
  NOTE: Be careful not to drop the check valve body, spring and accumulator piston.
REMOVE CHECK BALL BODY
Remove the check ball body and spring.

Fig 8: Removing Check Ball Body
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE 2 APPLY GASKETS

Fig 9: Removing Gaskets
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE SHIFT SOLENOID VALVE
Remove the 5 bolts and 5 shift solenoid valves.
INSTALL 5 SOLENOID VALVES
Install the 5 shift solenoid valves with the 5 bolts.

Torque:

Bolt A: 11 N.m (110 kgf.cm, 8 ft.lbf)

Bolt B: 11 N.m (110 kgf.cm, 8 ft.lbf)

Bolt length:

Bolt A: 12 mm (0.47 in.)

Bolt B:45 mm (1.77 in.)

Fig 10: Installing Solenoid Valves
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL APPLY GASKET
1. Coat 2 new apply gaskets with ATF.
2. Install the gaskets to the transaxle case.
  
  Fig 11: Installing Gaskets
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL CHECK BALL BODY
Install the spring and check ball body.

Fig 12: Installing Check Ball Body
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL VALVE BODY
1. Align the groove of the manual valve with the pin of the manual valve lever.
2. Temporarily install the valve body with the 12 bolts.
  Bolt length:
  
  Bolt A: 55 mm (2.17 in.)
  
  Bolt B:45 mm (1.77 in.)
  
  Bolt C: 32 mm (1.26 in.)
  
  Bolt D: 22 mm (0.87 in.)
  
  Fig 13: Installing Valve Body
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Temporarily install the detent spring and cover with the 2 bolts.
  Bolt length:
  
  Bolt B:45 mm (1.77 in.)
  
  Bolt E: 14 mm (0.55 in.)
4. Check that the manual valve lever contacts the center of the roller at the tip of the detent spring.
5. Tighten the 15 bolts.
  Torque: 11 N.m (110 kgf.cm, 8 ft.lbf)
INSTALL ATF TEMPERATURE SENSOR
Install the ATF temperature sensor with the lock plate and bolt.

Fig 14: Installing ATF Temperature Sensor
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Torque: 11 N.m (110 kgf.cm, 8 ft.lbf)
CONNECT 5 SHIFT SOLENOID VALVE CONNECTORS
INSTALL OIL STRAINER
1. Coat a new O-ring with ATF.
2. Install the O-ring to the oil strainer.
  
  Fig 15: Installing O-Ring To Oil Strainer
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Install the oil strainer with the 3 bolts.
  Torque: 11 N.m (110 kgf.cm, 8 ft.lbf)
  
  Fig 16: Installing Oil Strainer
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL 2 MAGNETS IN OIL PAN

Fig 17: Installing Magnets In Oil Pan

INSTALL OIL PAN AND GASKET
1. Install a new gasket to the oil pan.
2. Install the oil pan and a new gasket with the 19 bolts.
  Torque: 7.8 N.m (80 kgf.cm, 69 in.lbf)
  
  Fig 18: Installing Oil Pan
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL DRAIN PLUG
Install a new gasket and drain plug.

Torque: 49 N.m (500 kgf.cm, 36 ft.lbf)
FILL ATF AND CHECK ATF LEVEL (See PRE-CHECK )
INSTALL LH ENGINE UNDER COVER