On-Vehicle Repair

NOTE:

When working with FIPG material, you must observe the followings.
Using a razor blade and a gasket scraper, remove all old FIPG material from the sealing surfaces.
Thoroughly clean all components to remove all loose material. Clean both sealing surfaces with a non-residue solvent.
Apply FIPG in an approx. 1 mm (0.04 in.) wide bead along the sealing surface.
Parts must be assembled within 10 minutes of application. Otherwise, the FIPG material must be removed and reapplied.

REMOVE DRAIN PLUG AND DRAIN ATF
REMOVE OIL PAN
NOTE: Some fluid will remain in the oil pan.
1. Remove the 19 bolts.
  
  Fig 1: Removing Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Install the blade of SST between the transmission case and oil pan, cut off applied sealer and remove the oil pan. SST 09032-00100
NOTE: When removing the oil pan, be careful not to damage the oil pan flange.

Fig 2: Removing Oil Pan
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
EXAMINE PARTICLES IN PAN
Remove the magnets and use them to collect steel particles. Carefully look at the foreign matter and particles in the pan and on the magnets to anticipate the type of wear you will find in the transmission.

Steel (magnetic)...bearing, gear and clutch plate wear Brass (non-magnetic)...bushing wear

Fig 3: Removing Steel Particles From Pan
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE OIL STRAINER
1. Remove the 4 bolts and oil strainer.
  NOTE: Be careful as some fluid will come out with the oil strainer.
  
  Fig 4: Removing Oil Strainer
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Remove the 3 gaskets from the oil strainer.
Fig 5: Removing Gaskets
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
DISCONNECT 4 CONNECTORS FROM EACH SHIFT SOLENOID VALVE

Fig 6: Removing Connectors
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE VALVE BODY
Remove the 17 bolts and valve body.

Fig 7: Removing Valve Body
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE SHIFT SOLENOID VALVE
1. Remove the 2 bolts and 3 shift solenoid valves.
2. Turn the valve body, remove the bolt, lock plate and shift solenoid valve.
3. Remove the 3 O-rings from the 3 solenoid valves.
REMOVE DETENT SPRING
REMOVE MANUAL VALVE
INSTALL MANUAL VALVE
INSTALL DETENT SPRING
Torque: 10 N.m (100 kgf.cm, 7 ft.lbf)
INSTALL SOLENOID VALVE
1. Install 3 new O-rings to 3 shift solenoid valves.
2. Install the shift solenoid valve and lock plate with the bolt.
  Torque: 10 N.m (100 kgf.cm, 7 ft.lbf)
3. Install the 3 shift solenoid valves with the 2 bolts.
Torque: 10 N.m (100 kgf.cm, 7 ft.lbf)

Fig 8: Locating Shift Solenoid Valve
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL VALVE BODY
1. Align the groove of the manual valve with the pin of the lever.
  
  Fig 9: Installing Valve Body
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Install the valve body with the 17 bolts.
Torque: 11 N.m (110 kgf.cm, 8 ft.lbf)

Bolt length:

Bolt A: 23 mm (0.91 in.)

Bolt B: 28 mm (1.10 in.)

Bolt C: 36 mm (1.42 in.)

Fig 10: Installing Valve Body Bolts
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
CONNECT 4 CONNECTORS TO SHIFT SOLENOID VALVES

Fig 11: Installing Connectors
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL OIL STRAINER
1. Install 3 new gaskets.
  
  Fig 12: Installing Gaskets
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Install the oil strainer with the 4 bolts.
Torque: 10 N.m (100 kgf.cm, 7 ft.lbf)

Bolt length:

Bolt A: 14 mm (0.55 in.)

Bolt B: 20 mm (0.79 in.)

Bolt C: 23 mm (0.91 in.)

Fig 13: Installing Oil Strainer
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL OIL PAN
NOTE: Remove any packing material and be careful not to drop oil on the contacting surfaces of the transmission case and oil pan.
1. Install the 4 magnets in the indications of the oil pan.
  
  Fig 14: Installing Oil Pan
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Apply FIPG to the oil pan, as shown in the illustration.
  
  Fig 15: Installing Width Of FIPG
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  FIPG: Part No. 08826-01590, THREE BOND 1281 or equivalent
3. Install the 19 bolts and oil pan.
Torque: 7.4 N.m (75 kgf.cm, 65 in.lbf)
FILL AND CHECK ATF
1. Install a new gasket and the drain plug.
  Torque: 20 N.m (200 kgf.cm, 15 ft.lbf)
2. Fill new fluid through the filler pipe (See PRE-CHECK ).