This procedure replaces the torque converter clutch solenoid in the U660E automatic transmission, requiring transmission removal from the vehicle.

Warnings

Tools required

Parts

• Torque converter clutch solenoid × 1 — Use OEM specification
• Transmission pan gasket × 1 — Use OEM specification
• Transmission drain plug crush washer × 1 — Use OEM specification
• Valve body cover gasket × 1 — Use OEM specification

Fluids

• Toyota WS ATF — 10 qt

Preparation

1. Park vehicle on level surface and engage parking brake
2. Disconnect negative battery terminal and secure away from battery post
3. Raise vehicle and support securely on jack stands at all four corners
4. Remove engine undercovers and splash shields
5. Install engine support bar across engine bay or attach engine hoist to support engine weight
6. Allow transmission to cool if vehicle was recently operated

Procedure

1. 1

   Drain transmission fluid
   Place drain pan under transmission. Remove transmission drain plug and allow fluid to drain completely. Clean drain plug and install with new crush washer.
   Torque spec

   Transmission Drain Plug30 Nm (22 lb-ft)
2. 2

   Disconnect battery and air intake
   Remove air intake assembly from throttle body to air filter housing. Disconnect battery positive cable and secure away from terminals. Remove battery and battery tray for working clearance.
3. 3

   Disconnect transmission electrical connections
   Disconnect all transmission electrical connectors including: shift solenoid harness, vehicle speed sensor, park neutral position switch, and transmission range sensor. Label connections for reassembly.
4. 4

   Remove transmission cooler lines
   Disconnect transmission cooler lines from transmission using appropriate flare nut wrench. Cap open lines to prevent contamination. Have rags ready to catch residual fluid.
   ⚠Do not use standard wrenches on cooler line fittings as they may round off the soft aluminum nuts.
5. 5

   Remove front wheels and axle nuts
   Remove both front wheels. Remove cotter pins and loosen but do not remove axle shaft nuts (32mm) while vehicle is still on ground with brake applied. Remove nuts completely after raising vehicle.
6. 6

   Disconnect front axles
   Remove lower ball joint pinch bolts on both sides. Separate ball joints from steering knuckles. Pull steering knuckles outward and remove axle shafts from transmission. Support axles with wire to prevent damage to CV boots. Plug transmission openings to prevent fluid loss.
7. 7

   Remove exhaust front pipe and crossmember
   Disconnect oxygen sensors. Remove exhaust front pipe from manifold and catalytic converter. Remove front subframe crossmember to provide clearance for transmission removal.
   Torque spec

   Mounting Bolts58 Nm (43 lb-ft)
8. 8

   Remove starter motor
   Disconnect starter electrical connections. Remove starter mounting bolts and remove starter motor from transmission bell housing. Set aside in safe location.
   Torque spec

   Mounting Bolts58 Nm (43 lb-ft)
9. 9

   Support and remove transmission
   Position transmission jack under transmission pan with safety chain. Remove transmission mount bolts and crossmember. Remove torque converter access cover. Mark torque converter to flexplate orientation. Remove flexplate-to-torque converter bolts by rotating engine crankshaft. Remove remaining transmission-to-engine bolts. Carefully separate transmission from engine while ensuring torque converter remains with transmission.
   ⚠️Ensure torque converter is secured to transmission during removal to prevent it from falling out and causing injury.
   ⚠Lower transmission slowly and ensure all wiring and hoses are clear before fully lowering.
   Torque spec

   Flywheel Bolts95 Nm (70 lb-ft)

   Mounting Bolts58 Nm (43 lb-ft)
10. 10

    Remove transmission oil pan
    With transmission on work bench or secure surface, remove all transmission pan bolts in criss-cross pattern starting from center outward. Carefully separate pan from case and remove old gasket material. Clean pan and mating surface thoroughly.
    Torque spec

    Pan Bolts15 Nm (11 lb-ft)
11. 11

    Remove valve body cover and access solenoid
    Remove valve body cover screws and carefully lift cover. Locate the torque converter clutch solenoid on valve body assembly. Note solenoid orientation and electrical connector routing before removal.
    Torque spec

    Cover Screws10 Nm (8 lb-ft)
12. 12

    Replace torque converter clutch solenoid
    Disconnect solenoid electrical connector. Remove solenoid mounting bolt and carefully extract solenoid from valve body. Install new solenoid ensuring O-ring is properly seated. Torque mounting bolt to specification. Reconnect electrical connector ensuring it clicks into place.
    ⚠Do not overtighten solenoid bolt as valve body casting can crack. Use calibrated torque wrench.
    Torque spec

    Sensor Bolts10 Nm (8 lb-ft)
13. 13

    Reinstall valve body cover and pan
    Install new valve body cover gasket and reinstall cover. Install new transmission pan gasket on clean surface. Position pan and install bolts finger tight, then torque in criss-cross pattern from center outward.
    Torque spec

    Cover Screws10 Nm (8 lb-ft)

    Pan Bolts15 Nm (11 lb-ft)
14. 14

    Reinstall transmission to engine
    Ensure torque converter is fully seated in transmission (check depth measurement). Apply small amount of grease to torque converter hub. Align transmission to engine and install all mounting bolts. Align torque converter to flexplate using marks made during removal. Install and torque flexplate bolts in star pattern. Install torque converter access cover.
    ⚠Verify torque converter is fully seated before mating transmission to engine. Converter should be recessed approximately 15-20mm from bell housing face.
    Torque spec

    Flywheel Bolts95 Nm (70 lb-ft)

    Mounting Bolts58 Nm (43 lb-ft)

    Cover Screws10 Nm (8 lb-ft)
15. 15

    Reconnect all components and refill fluid
    Reinstall transmission crossmember and mounts. Install starter motor. Reconnect axle shafts ensuring they fully seat with audible click. Reconnect ball joints, install new axle nuts and cotter pins. Reinstall exhaust components. Reconnect all electrical connectors and cooler lines. Reinstall battery tray and battery. Fill transmission with Toyota WS ATF through dipstick tube using transmission fluid pump. Initial fill should be approximately 4 quarts.
    Torque spec

    Mounting Bolts58 Nm (43 lb-ft)

    Sensor Bolts10 Nm (8 lb-ft)

Reassembly

1. Ensure all electrical connectors are fully seated and locked
2. Verify axle shafts are fully engaged in transmission with retaining clips seated
3. Double-check all transmission mounting bolts are torqued to specification
4. Confirm transmission cooler lines are tight and properly routed
5. Reinstall all undercovers and splash shields

Verification

• Start engine and check for fluid leaks around pan, cooler lines, and axle seals
• With engine idling and parking brake applied, shift through all gear positions, pausing 3 seconds in each position
• Check transmission fluid level with engine at operating temperature in Park on level ground
• Add fluid as needed to bring level to HOT range on dipstick
• Road test vehicle and verify smooth shifts and proper torque converter lockup (typically occurs above 45 mph in 4th gear or higher)
• Scan for diagnostic trouble codes and verify no transmission-related codes are present
• Re-check fluid level after road test and top off if necessary
• Verify no fluid leaks after test drive

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