Toyota Cressida and Van 1983-1990

Transmission Assembly

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REMOVAL & INSTALLATION



Van


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Fig. Fig. 1 When removing the manual transmission on the 2WD Van, the rear engine mount must be unbolted from the vehicle



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Fig. Fig. 2 On the 4WD Van, matchmark the transfer case and separate it from the manual transmission



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Fig. Fig. 3 Remove the transfer case control cable on the 4WD Van models during manual transmission removal



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Fig. Fig. 4 On the 2WD Van models, disconnect and remove the transmission case control cables



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Fig. Fig. 5 On all Van models, remove the clutch slave cylinder from the manual transmission assembly



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Fig. Fig. 6 Prior to transmission removal, remove the rear engine mount on the 4WD Van

  1. Disconnect the negative battery terminal.
  2.  
  3. Raise the vehicle and support safely. Drain the transmission oil.
  4.  
  5. On the 2WD models, remove the driveshaft as follows:
  6.  
    1. Place matchmarks on the differential and the driveshaft flange.
    2.  
    3. Remove the 4 bolts and nuts, disconnect the driveshaft from the differential.
    4.  
    5. Pull out the driveshaft yoke from the transmission and place a container under the extension housing to catch any oil that spills out.
    6.  

  7. On the 4WD models, remove the rear driveshafts as follows:
  8.  
    1. Place matchmarks on the differential and the driveshaft flange.
    2.  
    3. Remove the 4 bolts, washers and nuts, disconnect the driveshaft from the differential.
    4.  
    5. Place matchmarks on the transfer case and the driveshaft flanges.
    6.  
    7. Remove the 4 bolts, washers and nuts, disconnect the driveshaft from the transfer case.
    8.  

  9. On the 4WD models, remove the front driveshafts as follows:
  10.  
    1. Remove the 2 differential support bracket retaining bolts.
    2.  
    3. Remove the 4 bolts and nuts, disconnect the differential support member from the body.
    4.  
    5. Place matchmarks on the differential and the driveshaft flanges.
    6.  
    7. Remove the 4 bolts, washers and nuts, disconnect the driveshaft from the differential.
    8.  
    9. Pull out the driveshaft yoke from the transfer case and place a container under the extension housing to catch any oil that spills out.
    10.  

  11. Disconnect the reverse light and transfer indicator switches, if equipped.
  12.  
  13. Disconnect the speedometer cable and ground cable.
  14.  
  15. Disconnect the transmission control cables by removing the nuts and removing the retainers from the bracket. If equipped with 4WD, disconnect the transfer control cable by removing the retaining clip and washer.
  16.  
  17. Remove the clutch slave cylinder.
  18.  
  19. Remove the front exhaust pipe clamp from the bracket and disconnect the pipe from the exhaust manifold.
  20.  
  21. Remove the starter and control cable bracket.
  22.  
  23. Using the proper equipment, jack up the transmission enough to take the weight off of the mount and remove either the rear mount (2WD) or the rear mount through bolt (4WD).
  24.  
  25. On the 2WD models, disconnect the engine rear mounting. On the 4WD models, remove the rear mounting bolt.
  26.  
  27. Remove the transmission mounting bolts.
  28.  
  29. On the 2WD lower the transmission jack, pull the transmission down and toward the rear of the vehicle.
  30.  
  31. On the 4WD lower the transmission jack, pull the transmission and transfer case assembly down and toward the rear of the vehicle.
  32.  
  33. On the 4WD models, remove the transfer case from the transmission as follows:
  34.  
    1. Remove the rear engine mounting.
    2.  
    3. Stand the transmission straight up and remove the transfer case retaining bolts.
    4.  
    5. Pull the transfer case straight up and remove it from the transmission.
    6.  


To install:

  1. On the 4WD models, install the transfer case with a new gasket onto the transmission as follows:
  2.  
    1. Install the transfer case straight down onto the transmission.
    2.  
    3. Install the transfer case retaining bolts and tighten them to 27 ft. lbs. (37 Nm). Be sure to apply a suitable thread sealer to the 2 front bolts.
    4.  
    5. Install the rear engine mounting and retaining bolts. Tighten the bolts to 21 ft. lbs. (28 Nm).
    6.  

  3. Place the transmission in the proper installation position on the transmission jack and align the input shaft spline with the clutch disc spline and push the transmission fully into position. Be sure to apply some multi-purpose grease to the input shaft splines so as to aid in the installation of the transmission.
  4.  
  5. Install the transmission mounting bolts and torque them to 53 ft. lbs. (72 Nm). Tighten the stiffener plate bolt to 27 ft. lbs. (37 Nm).
  6.  
  7. On the 2WD models, connect the rear engine mounting bolt and tighten the bolt to 9 ft. lbs. (12 Nm).
  8.  
  9. On the 4WD models, connect the rear engine mounting bolt and tighten the bolt to 36 ft. lbs. (49 Nm).
  10.  
  11. Install the starter and control cable bracket.
  12.  
  13. Install the exhaust pipe to the manifold, tighten the bolts to 46 ft. lbs. (62 Nm). Install the clamp.
  14.  
  15. Install the clutch slave cylinder.
  16.  
  17. Connect the transfer control cable, if equipped and install a new clip.
  18.  
  19. Install the transmission control cables.
  20.  
  21. Connect the speedometer cable and the ground strap.
  22.  
  23. Connect the reverse light switch and transfer indicator switch, if equipped.
  24.  
  25. On the 2WD models install the driveshafts as follows:
  26.  
    1. Insert the yoke into the transmission.
    2.  
    3. Align the matchmarks on the flanges and attach the flanges with the 4 bolts, washers and nuts. Tighten the bolts and nuts 54 ft. lbs. (74 Nm).
    4.  

  27. On the 4WD models install the front driveshafts as follows:
  28.  
    1. Insert the yoke into the transfer case.
    2.  
    3. Align the matchmarks on the flanges and attach the flanges with the 4 bolts, washers and nuts. Tighten the bolts and nuts 31 ft. lbs. (42 Nm).
    4.  
    5. Connect the differential support member to the body with the 4 bolts, washers and nuts. Tighten the bolts and nuts 70 ft. lbs. (95 Nm).
    6.  
    7. Install the 2 bolts to the bracket. Tighten the bolts until they are snug.
    8.  

  29. On the 4WD models, install the rear driveshafts as follows:
  30.  
    1. Align the matchmarks on the flanges and attach the flanges with the 4 bolts, washers and nuts. Tighten the bolts and nuts 54 ft. lbs. (74 Nm).
    2.  
    3. Connect the rear driveshaft to the differential by aligning the matchmarks on the flanges and attach the flanges with the 4 bolts, washers and nuts. Tighten the bolts and nuts 54 ft. lbs. (74 Nm).
    4.  

  31. Refill the transmission with the proper lubricant.
  32.  
  33. Lower the vehicle and connect the negative battery cable.
  34.  
  35. Road test the vehicle and check for leaks.
  36.  

Cressida

Manual transmissions are not available on the 1988-90 Cressida models.

  1. Disconnect the negative battery cable.
  2.  
  3. Drain the radiator and remove the upper radiator hose.
  4.  
  5. Remove the console box assembly.
  6.  
  7. Remove the shift lever assembly.
  8.  
  9. Raise and support the vehicle safely. Drain the transmission fluid.
  10.  
  11. If the vehicle is equipped with power steering, remove the steering gear housing (as outlined later in this guide). It may be possible to remove the gear and properly suspend it out of the way without disconnecting the fluid lines.
  12.  
  13. Remove the intermediate driveshaft as follows:
  14.  
    1. Remove the driveshaft flange reinforcement.
    2.  
    3. Place matchmarks on the driveshaft and differential flanges.
    4.  
    5. Remove the 4 bolts and nuts and disconnect the driveshaft flange from the differential flange.
    6.  
    7. Place matchmarks on the driveshaft flange and the transmission yoke flange.
    8.  
    9. Remove the 4 bolts and nuts and disconnect the driveshaft flange from the transmission yoke flange.
    10.  
    11. Remove the center support bearing bracket retaining bolts.
    12.  
    13. Remove the center support bearing from the bearing support bracket.
    14.  
    15. Pull the driveshaft yoke out of the transmission and place a drain pan underneath so as to catch any oil that may leak out.
    16.  

  15. Disconnect the exhaust pipe at the rear side of the converter. Remove the 2 rubber hangers. Remove the pipe clamp from the transmission case.
  16.  
  17. Disconnect the speedometer cable. Disconnect the back-up light switch electrical wiring.
  18.  
  19. Remove the clutch release cylinder. Remove the starter.
  20.  
  21. Support the engine and the transmission using a proper transmission jack and a suitable engine holding fixture (such as a chain hoist).
  22.  
  23. Remove the rear engine crossmember assembly.
  24.  
  25. Remove the exhaust pipe bracket and two stiffener plates.
  26.  
  27. Remove the transmission-to-engine retaining bolts. Carefully lower the transmission down and to the rear of the vehicle.
  28.  

To install:

  1. Place the transmission in the proper installation position on the transmission jack and align the input shaft spline with the clutch disc spline and push the transmission fully into position. Be sure to apply some multi-purpose grease to the input shaft splines so as to aid in the installation of the transmission.
  2.  
  3. Install the transmission mounting bolts and tighten them to 47 ft. lbs. (64 Nm). Install the 2 stiffener bolts and exhaust pipe bracket.
  4.  
  5. Install the rear engine crossmember and bolts. Tighten the bolts to 19 ft. lbs. (25 Nm).
  6.  
  7. Install the starter assembly and the clutch release cylinder.
  8.  
  9. Reconnect the speedometer cable. Attach the back-up light switch electrical connector.
  10.  
  11. Install the pipe clamp to the transmission case. Install the 2 rubber hangers and reconnect the exhaust pipe at the rear side of the converter.
  12.  
  13. Install the intermediate driveshaft as follows:
  14.  
    1. Install the driveshaft yoke into the transmission assembly.
    2.  
    3. Install the center support bearing into the bearing support bracket.
    4.  
    5. Install the center support bearing bracket and retaining bolts. Check that the center line of the center bearing is set to the center line of the bracket when the vehicle is in a no-load condition, adjust as necessary. Tighten the bolts to 30 ft. lbs. (40 Nm).
    6.  
    7. Reconnect the driveshaft flange to the transmission yoke flange. Install the retaining nuts and bolts and torque them to 31 ft. lbs.
    8.  
    9. Reconnect the driveshaft flange to the differential flange. Install the retaining nuts and bolts and tighten them to 31 ft. lbs.
    10.  
    11. Install the driveshaft flange reinforcement.
    12.  

  15. Install the steering gear housing assembly (as outlined later in this guide).
  16.  
  17. Refill the transmission with the proper lubricant.
  18.  
  19. Lower the vehicle. Install the shift lever assembly.
  20.  
  21. Install the console box assembly.
  22.  
  23. Install the upper radiator hose. Close the radiator drain petcock and refill the coolant system.
  24.  
  25. Reconnect the negative battery cable.
  26.  
  27. Road test the vehicle and check for leaks.
  28.  


CAUTION
The clutch driven disc may contain asbestos, which has been determined to be a cancer causing agent. Never clean the clutch surfaces with compressed air. Avoids inhaling any dust from the clutch surface. When cleaning the clutch surfaces, use a commercially available disc brake cleaning fluid.

 
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