Installation
AB60E AUTOMATIC TRANSMISSION ASSEMBLY:
INSTALLATION
1. INSTALL TORQUE CONVERTER ASSEMBLY
(a) Using a vernier caliper and a straightedge, measure dimension A between the transmission and the end surface of the drive plate.
Standard distance A:
9.3 mm (0.366 in.)
(b) Install the torque converter to the transmission housing.
(c) Using a vernier caliper and a straightedge, measure dimension B shown in the illustration and check that B is greater than A measured in the first step.
Standard distance B:
10.3 mm (0.406 in.) or more
2. INSTALL TRANSMISSION CONTROL CABLE BRACKET
(a) Install the bracket with the 2 bolts.
Torque: 12 Nm (122 kgf-cm, 9 ft-lbf)
3. INSTALL WIRE HARNESS CLAMP BRACKET
(a) Install the front bracket LH with the bolt.
Torque: 8.0 Nm (82 kgf-cm, 71 in-lbf)
(b) Install the rear bracket LH with the bolt.
Torque: 29 Nm (296 kgf-cm, 21 ft-lbf)
(c) Install the rear engine bracket with the bolt.
Torque: 8.0 Nm (82 kgf-cm, 71 in-lbf)
4. INSTALL TRANSMISSION OIL COOLER ASSEMBLY (w/o Trailer Towing System)
(a) Coat 4 new O-rings with ATF.
(b) Install the 4 O-rings, transmission oil cooler spacer and transmission oil cooler to the automatic transmission assembly with the 3 bolts.
Torque: 21 Nm (214 kgf-cm, 25 ft-lbf)
5. INSTALL TRANSMISSION OIL COOLER ASSEMBLY (w/ Trailer Towing System)
(a) Coat 4 new O-rings with ATF.
(b) Install the 4 O-rings, transmission oil thermostat and transmission oil cooler to the automatic transmission assembly with the 3 bolts.
Torque: 21 Nm (214 kgf-cm, 25 ft-lbf)
6. INSTALL AUTOMATIC TRANSMISSION ASSEMBLY
(a) Install the transmission with the 10 bolts.
for 17 mm head bolt A - Torque: 71 Nm (724 kgf-cm, 52 ft-lbf)
for 14 mm head bolt B - Torque: 37 Nm (377 kgf-cm, 27 ft-lbf)
7. CONNECT NO. 2 WATER BY-PASS PIPE (w/o Trailer Towing System)
(a) Connect the 2 water by-pass hoses with the 2 clips and install the water by-pass pipe with the bolt.
Torque: 18 Nm (184 kgf-cm, 13 ft-lbf)
NOTE: Make sure the pinching portion of each clip is facing the direction shown in the illustration.
8. CONNECT NO. 2 WATER BY-PASS PIPE (w/ Trailer Towing System)
(a) Connect the 2 oil cooler hoses to the transmission oil thermostat.
NOTICE:
- Make sure the pinching portion of each clip is facing the direction shown in the illustration.
- Make sure the paint portion of each hose is facing outward.
(b) Connect the 2 water by-pass hoses with the 2 clips and install the water by-pass pipe with the bolt.
Torque: 18 Nm (184 kgf-cm, 13 ft-lbf)
NOTE: Pinching portion of clip shall be directed as shown in the illustration.
9. CONNECT BREATHER PLUG HOSE
(a) Connect the breather plug hose to the harness clamp bracket.
10. CONNECT WIRE HARNESS AND CONNECTOR
(a) Connect the park/neutral start switch connector, 2 transmission wire connectors and 2 speed sensor connectors.
HINT: Push up the lever until the claw of the transmission wire connector makes a connection sound.
(b) Connect the harness clamp with the bolt.
Torque: 8.2 Nm (84 kgf-cm, 73 in-lbf)
(c) Connect the 3 connector clamps and 4 harness clamps.
(d) Tilt up the automatic transmission.
(e) Connect the ground cable with the bolt.
Torque: 5.5 Nm (56 kgf-cm, 49 in-lbf)
11. INSTALL REAR NO. 1 ENGINE MOUNTING INSULATOR
(a) Install the rear engine mounting insulator to the transmission with the 4 bolts.
Torque: 40 Nm (407 kgf-cm, 30 ft-lbf)
12. INSTALL NO. 3 FRAME CROSSMEMBER SUB-ASSEMBLY
(a) Install the frame crossmember to the rear engine mounting insulator with the 4 bolts.
Torque: 16 Nm (163 kgf-cm, 12 ft-lbf)
(b) Install the frame crossmember with the 4 bolts, 4 washers and 4 nuts.
Torque: 110 Nm (1122 kgf-cm, 81 ft-lbf)
13. INSTALL DRIVE PLATE AND TORQUE CONVERTER CLUTCH SETTING BOLT
(a) Turn the crankshaft to gain access to the 6 bolts and install the bolts while holding the crankshaft pulley set bolt with a wrench.
Torque: 53 Nm (535 kgf-cm, 39 ft-lbf)
NOTE: First install the black colored bolt and then the remaining 5 bolts.
(b) Install the flywheel housing side cover.
14. INSTALL STARTER ASSEMBLY
(a) Install the starter (Installation).
15. CONNECT TRANSMISSION CONTROL CABLE ASSEMBLY
(a) Connect the control cable with a new clip and the nut.
Torque: 14 Nm (143 kgf-cm, 10 ft-lbf)
NOTE: When connecting the cable to the transmission control shaft lever, make sure the cable's L bracket faces the outside of the vehicle.
16. INSTALL PROPELLER SHAFT ASSEMBLY
(a) Install the propeller shaft (Service and Repair).
17. INSTALL FRONT EXHAUST PIPE ASSEMBLY
(a) for Regular Cab Standard Deck:
Install the front exhaust pipe (Installation).
(b) except Regular Cab Standard Deck:
Install the front exhaust pipe (Installation).
18. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
NOTE: Some systems need to be initialized after the cable is reconnected (Repair Instruction - Initialization).
19. ADD AUTOMATIC TRANSMISSION FLUID
(a) Add automatic transmission fluid (Procedures).
20. ADD ENGINE COOLANT (Service and Repair)
21. CHECK FOR ENGINE COOLANT LEAK (Testing and Inspection)
22. ADJUST SHIFT LEVER POSITION (Shift Lever Assembly (for Column Shift Type))
23. INSPECT SHIFT LEVER POSITION (Shift Lever Assembly (for Column Shift Type))
24. CHECK FOR EXHAUST GAS LEAK (Installation)
25. INSTALL NO. 1 ENGINE UNDER COVER
26. RESET MEMORY
(a) Perform the RESET MEMORY procedures (A/T initialization) (Programming and Relearning).