Installation

AB60F AUTOMATIC TRANSMISSION / TRANSAXLE: AUTOMATIC TRANSMISSION ASSEMBLY: INSTALLATION

INSTALLATION

1. INSTALL TORQUE CONVERTER CLUTCH ASSEMBLY

(a) Using a vernier caliper and straightedge, measure dimension A between the transmission and the end surface of the drive plate.
(b) Install the torque converter to the transmission housing.

(c) Using a vernier caliper and straightedge, measure dimension B shown in the illustration and check that B is more than A measured in the first step.
Standard distance:
B = A + 1.00 mm (0.0394 in.) or more
2. 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 bracket RH with the bolt.
Torque: 29 Nm (296 kgf-cm, 21 ft-lbf)
(d) Install the front bracket RH with the bolt.
Torque: 8.0 Nm (82 kgf-cm, 71 in-lbf)
(e) Install the rear engine bracket with the bolt.
Torque: 8.0 Nm (82 kgf-cm, 71 in-lbf)
3. INSTALL TRANSFER ASSEMBLY

(a) Install the transfer with the 8 bolts.
Torque: 40 Nm (408 kgf-cm, 30 ft-lbf)
NOTE: Be careful not to damage the oil seal of the transfer adapter.

(b) Install the transfer case lower protector with the 7 bolts.
Torque: 14 Nm (143 kgf-cm, 10 ft-lbf)
(c) Connect the clamp of grand cable to the transfer case lower protector.

(d) Attach the 3 breather hose clamps to connect the transfer breather hose to the automatic transmission breather tube.

4. CONNECT BREATHER PLUG HOSE
(a) Connect the 2 breather plug hoses to the harness clamp bracket.

5. INSTALL TRANSMISSION OIL COOLER ASSEMBLY
(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.
(c) Temporarily install bolt A. Install the bolts labeled B and tighten them to the specified torque. Then tighten bolt A to the specified torque.
Torque: 21 Nm (214 kgf-cm, 15 ft-lbf)

6. INSTALL AUTOMATIC TRANSMISSION ASSEMBLY
NOTE: Check that the 2 straight pins are attached to the engine side.

(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 TRANSMISSION OIL COOLER HOSE
(a) Connect the 2 transmission 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 mark of each hose is facing outward.

8. CONNECT NO. 2 WATER BY-PASS PIPE

(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)

NOTICE:
- Make sure the pinching portion of each clip is facing the direction shown in the illustration.
- Make sure the paint mark of each hose is facing outward.

9. CONNECT WIRE HARNESS AND CONNECTOR

(a) Connect the park/neutral position switch connector, 2 transmission wire connectors, 2 speed sensor connectors and 3 transfer control side connectors.
HINT: Push up the lever until the claw of the transmission wire connector makes a connection sound.

(b) Connect the 4 connector clamps and 6 harness clamps.
(c) Connect the wire harness with the bolt.
Torque: 8.0 Nm (82 kgf-cm, 71 in-lbf)
(d) Tilt up the automatic transmission.

(e) Connect the ground cable with the bolt.
Torque: 8.4 Nm (86 kgf-cm, 74 in-lbf)

10. INSTALL REAR NO. 1 ENGINE MOUNTING INSULATOR
(a) Install the rear engine mounting insulator to the transmission with the 4 bolts.
Torque: 59 Nm (602 kgf-cm, 44 ft-lbf)
(b) Install the engine mounting heat insulator with the 2 bolts.
Torque: 12 Nm (122 kgf-cm, 9 ft-lbf)
11. INSTALL NO. 2 FRAME CROSSMEMBER SUB-ASSEMBLY

(a) Install the frame crossmember to the rear engine mounting insulator with the 4 bolts.
Torque: 37 Nm (377 kgf-cm, 27 ft-lbf)

(b) Install the frame crossmember to the frame with the 4 bolts and 4 nuts.
Torque: 110 Nm (1122 kgf-cm, 81 ft-lbf)

(a) Turn the crankshaft to gain access to the installation locations of 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.
13. INSTALL STARTER ASSEMBLY

14. INSTALL STARTER COVER

15. INSTALL EXHAUST MANIFOLD SUB-ASSEMBLY RH Installation

16. INSTALL NO. 1 EXHAUST MANIFOLD HEAT INSULATOR Installation

17. INSTALL ENGINE OIL LEVEL DIPSTICK GUIDE Installation

18. INSTALL NO. 2 MANIFOLD STAY Installation

19. INSTALL NO. 1 MANIFOLD STAY Installation

20. INSTALL FRONT EXHAUST PIPE ASSEMBLY Installation

21. INSTALL FRONT NO. 2 EXHAUST PIPE ASSEMBLY Installation

22. INSTALL CENTER EXHAUST PIPE ASSEMBLY Installation

23. INSTALL TAILPIPE ASSEMBLY Installation

24. INSTALL PROPELLER SHAFT ASSEMBLY
(a) Install the propeller shaft Installation.
25. INSTALL FRONT PROPELLER SHAFT ASSEMBLY
(a) Install the front propeller shaft Installation.

26. CONNECT FLOOR SHIFT GEAR SHIFTING ROD SUB-ASSEMBLY
(a) Connect the gear shifting rod to the transmission control shaft lever RH with the pin and a new clip.
27. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
28. ADD AUTOMATIC TRANSMISSION FLUID
(a) Add automatic transmission fluid Procedures.
29. ADD ENGINE COOLANT Service and Repair

30. INSPECT FOR ENGINE COOLANT LEAK Testing and Inspection

31. INSPECT SHIFT LEVER POSITION
(a) When moving the shift lever from P to R with the engine switch on (IG) and the brake pedal depressed, make sure that it moves smoothly and correctly into position.
(b) Check that the shift lever does not stop when moving the shift lever from R to P, and check that the shift lever does not stick when moving the shift lever from D to S.
(c) Start the engine and make sure that the vehicle moves forward after moving the shift lever from N to D and moves rearward after moving the shift lever to R.
If there are problems during the above inspections, perform the adjustment using the following procedures.
(1) Move the shift lever to N

(2) Loosen the nut of the floor shift gear shifting rod. Then, with the lever of the floor shift assembly lightly pushed towards the rear of the vehicle, tighten the nut.
Torque: 13 Nm (133 kgf-cm, 10 ft-lbf)
32. INSPECT FOR EXHAUST GAS LEAK Installation

33. INSTALL UPPER RADIATOR SUPPORT SEAL

34. INSTALL OIL PAN PROTECTOR ASSEMBLY
(a) Install the oil pan protector with the 4 bolts.
Torque: 63 Nm (642 kgf-cm, 46 ft-lbf)

35. INSTALL NO. 1 ENGINE UNDER COVER
(a) Install the under cover with the 6 bolts.
Torque: 29 Nm (296 kgf-cm, 21 ft-lbf)

36. INSTALL NO. 2 ENGINE UNDER COVER
(a) Install the under cover with the 6 bolts.
Torque: 29 Nm (296 kgf-cm, 21 ft-lbf)
37. INSTALL REAR FENDER SPLASH SHIELD SUB-ASSEMBLY LH

38. INSTALL REAR FENDER SPLASH SHIELD SUB-ASSEMBLY RH

39. RESET MEMORY
(a) Perform the Reset Memory procedures (A/T initialization) Programming and Relearning.