Toyota Pick-ups/Land Cruiser/4Runner 1989-1996

Transmission Assembly

Print

REMOVAL & INSTALLATION




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

Pick-Up and 4Runner
2WD MODELS

See Figures 1, 2, 3 and 4

  1. Disconnect the negative battery cable.
  2.  
  3. Remove the four bolts holding the fan shroud.
  4.  



Click image to see an enlarged view

Fig. Fig. 1: Exploded view of the manual transmission and related components-2WD Pick-Up

  1. Remove the shift lever boot retainer. Pull up the boot and cover the shift lever cap with a cloth. Press down on the shift lever cap and turn it counterclockwise to remove it. Remove the shift lever.
  2.  
  3. Raise the truck and support it on safety stands. Double check the supports for secure placement.
  4.  
  5. Drain the fluid from the transmission.
  6.  
  7. Remove the driveshaft and plug the extension housing to prevent oil seepage.
  8.  
  9. Disconnect the speedometer cable.
  10.  
  11. Disconnect the back-up light switch wire.
  12.  
  13. Remove the exhaust pipe clamp from the bracket; disconnect the exhaust pipe at the manifold and remove the clamp bracket from the clutch housing. For vehicles with 3VZ-E engines, remove the pipe bracket from the clutch housing first, then disconnect the pipe at the manifold and from the front of the catalytic converter.
  14.  
  15. Remove the clutch slave cylinder mounting bolts and pipe bracket; position the cylinder out of the way. Do not disconnect the fluid line.
  16.  
  17. Remove the four bolts holding the stabilizer (sway) bar.
  18.  
  19. Remove the four bolts holding the frame auxiliary crossmember.
  20.  
  21. Remove the 4 rear engine mount bolts at the extension housing. Position a block of wood on a floor jack and raise the engine slightly. Remove the 4 rear mount-to-support member bolts and remove the rear engine mount. Remove the rear engine mount from the transmission.
  22.  



Click image to see an enlarged view

Fig. Fig. 2: A piece of wood must be taped to the front crossmember

  1. Tape a piece of wood about 8 / 10 in. (20mm) thick onto the front crossmember and then lower the transmission.
  2.  
  3. Remove the starter. Remove the stiffener plate bolts.
  4.  
  5. Remove the remaining transmission housing bolts.
  6.  
  7. With a floor jack under the transmission case, pull it toward the rear and slowly lower the front end until it can be removed from the truck. On models with the 3VZ-E engine and R150 transmission, turn the transmission about 45° clockwise. Slide it toward the rear, lower the front and then remove it from the truck.
  8.  

To install:
  1. Insert the extension housing between the crossmember and the floor. Slide the transmission forward. Position the transmission case so the input shaft splines align with the clutch disc and push it fully into position. Install the 2 upper mounting bolts.
  2.  
  3. Install the transmission housing and stiffener plate bolts. Install the starter. Tighten the transmission bolts to 53 ft. lbs. (72 Nm) and the stiffener plate bolts to 27 ft. lbs. (37 Nm). Tighten the starter bolt to 29 ft. lbs. (39 Nm).
  4.  
  5. Install the rear engine mount and bracket. Tighten the bolts to 19 ft. lbs. (25 Nm).
  6.  
  7. Raise the engine slightly and position the rear engine mount in the support member and tighten the bolts to 43 ft. lbs. (59 Nm).
  8.  
  9. Lower the transmission until it rests on the rear mount. Install the 4 bolts and tighten them to 22 ft. lbs. (29 Nm).
  10.  



Click image to see an enlarged view

Fig. Fig. 3: Engine series 22R-E (top) and 3VZ-FE (bottom) bolt hole locations on 2WD manual transmissions: "A'' is for transmission mounting, "B'' is for the stiffener, and "C'' is for the starter

  1. Remove the piece of wood from the front crossmember.
  2.  
  3. Install the exhaust pipe, bracket and clamp. Tighten the exhaust pipe bolts to 46 ft. lbs. (62 Nm). On 22R-E engines, tighten the upper pipe bracket bolts to 14 ft. lbs. (19 Nm) and the lower one to 51 ft. lbs. (69 Nm). On 3VZ-E engines, tighten the pipe bolts at the catalyst to 29 ft. lbs. (39 Nm.)
  4.  
  5. Install the clutch slave cylinder and tube bracket. Tighten the pipe bracket bolts to 53 ft. lbs. (72 Nm). Tighten the slave cylinder bolts to 9 ft. lbs. (12 Nm).
  6.  



Click image to see an enlarged view

Fig. Fig. 4: Exploded view of the manual transmission and related components-W56 with 22R-E engine

  1. Install the stabilizer bar retaining bolts and tighten them to 22 ft. lbs. (29 Nm).
  2.  
  3. Install the frame auxiliary crossmember, tightening the bolts to 70 ft. lbs. (95 Nm).
  4.  
  5. Connect the speedometer cable. Connect the back-up light switch.
  6.  
  7. Remove the extension housing plug and install the driveshaft.
  8.  
  9. Fill the transmission with oil and lower the truck.
  10.  
  11. Apply multi-purpose grease to the shift lever; align the groove of the shift lever cap and the pin part of the case. Cover the shift lever cap with a cloth. Press down on the shaft and turn it clockwise to install. Install the shift lever boot and retainer with the four screws.
  12.  
  13. Install the fan shroud bolts.
  14.  
  15. Connect the battery cable and road test the truck.
  16.  

4WD MODELS

See Figure 5



Click image to see an enlarged view

Fig. Fig. 5: Exploded view of the manual transmission and related components-R150F with 3VZ-FE engine

The manual transmission is removed with the transfer case attached.

  1. Disconnect the battery cables at the battery, negative cable first.
  2.  
  3. Remove the retaining bolts holding the fan shroud.
  4.  
  5. On 3VZ-E engines, loosen the clamp on the heater hose at the firewall and move the clamp up the heater hose out of the way.
  6.  
  7. Remove the four screws holding the shift lever boot retainer. Pull up the boot and cover the shift lever cap with a cloth. Press down on the shift lever cap, rotate it counterclockwise and remove the shift lever.
  8.  
  9. Using needle nose pliers, remove the transfer case shift lever retainer snapring, then remove the shift lever.
  10.  
  11. Raise the vehicle and support is securely with jackstands. Double check the placement and security of the stand.
  12.  
  13. Drain the lubricant from both the transmission and the transfer case.
  14.  
  15. Matchmark the driveshaft flanges and the differential pinion flanges to indicate their relationships. These marks must be aligned during installation. Remove the four bolts from each end of the front driveshaft and remove the driveshaft assembly. On vehicles with G58 and R150F transmissions, it is necessary to remove the propeller shaft dust cover before the shaft is removed.
  16.  
  17. Matchmark the rear driveshaft and the slip yoke to indicate their relationships. These marks must be aligned during installation.
  18.  
  19. Remove the four bolts from the rearward flange of the rear driveshaft. Lower the driveshaft out of the vehicle. Remove the four bolts from the slip yoke flange then remove the flange and yoke assembly.
  20.  
  21. Disconnect the speedometer cable, reverse lamp switch connector and transfer switch connector.
  22.  
  23. On 3VZ-E engines, remove the exhaust pipe clamp, the exhaust bracket from the clutch housing and disconnect the exhaust pipe at the exhaust manifold. Disconnect the exhaust pipe from the front of the catalyst and remove the pipe. On 22R-E engines, remove the bolts holding the exhaust pipe clamp to the transmission and disconnect the exhaust pipe at the manifold. Support the pipe out of the way with wire or rope.
  24.  
  25. Disconnect the clutch slave cylinder retaining bolts and move the cylinder out of the way with the line attached. On 22R-E engines, the piping bracket must also be removed.
  26.  
  27. On 3VZ-E engines, support the front differential with a floor jack; remove the 3 bolts holding the front differential.
  28.  
  29. Remove the 4 bolts holding the stabilizer (sway) bar brackets.
  30.  
  31. Remove the 4 bolts from the rear engine mount. Raise the transmission slightly with a jack. Remove the eight bolts from the side frame rails and remove the No. 2 crossmember.
  32.  
  33. For 22R-E engines, place a piece of wood between the engine oil pan and the front axle.
  34.  
  35. Lower the transmission and transfer case.
  36.  
  37. Remove the two bolts holding the starter; place or hang the starter alongside the motor.
  38.  
  39. Remove the exhaust pipe bracket and the bolts in the stiffener plate.
  40.  
  41. Support the transmission and transfer case with a jack. Remove the remaining transmission mounting bolts.
  42.  
  43. Remove the transmission by moving it rearward; once clear, lower the front of the transmission and remove the unit from the vehicle.
  44.  
  45. Remove the breather hose between the transfer case and the transmission case.
  46.  
  47. Remove the rear engine mount from the transmission case.
  48.  
  49. If equipped with a dynamic damper at the rear of the case, remove it.
  50.  
  51. Remove the driveshaft upper dust cover from the bracket. Remove the mounting bolts for the transfer adapter.
  52.  
  53. Pull the transfer case straight off the end of the transmission. Do not damage the transfer case rear oil seal during removal.
  54.  

To install:
  1. Move the two shift fork shafts to the High-4 position.
  2.  
  3. Apply multi-purpose grease to the adaptor oil seal. Install a new gasket on the transfer case adapter.
  4.  
  5. Install the transfer case to the transmission. Install and tighten the retaining bolts to 28 ft. lbs. (38 Nm).
  6.  
  7. Install the dust cover bolt to the bracket. Tighten to 17 ft. lbs. (23 Nm) for R150F and G58 units and 29 ft. lbs. (39 Nm) for W56 units.
  8.  
  9. Install the rear engine mount, tightening the bolts to 19 ft. lbs. (25 Nm). Install the dynamic damper if it was removed and tighten the bolts to 27 ft. lbs. (37 Nm). Install the breather hose.
  10.  
  11. Support the transmission assembly on a jack. Move the unit into installation position and align the input shaft spline with the clutch disc. Push the transmission fully into position.
  12.  
  13. Install the transmission and stiffener bolts. On 3VZ-E engines, install the starter. Tighten the transmission bolts to 53 ft. lbs. (72 Nm), the stiffener bolts to 27 ft. lbs. (37 Nm). Tighten the starter bolts to 29 ft. lbs. (39 Nm).
  14.  
  15. Raise the transmission slightly with a jack. Install the No. 2 frame crossmember and tighten the bolts to 70 ft. lbs. (95 Nm).
  16.  
  17. Lower the transmission assembly. Install the 4 bolts to the engine rear mount; tighten them to 9 ft. lbs. (13 Nm).
  18.  
  19. Install the stabilizer bracket bolts, tightening them to 22 ft. lbs. (29 Nm).
  20.  
  21. For 22R-E engines, remove the piece of wood from the front axle.
  22.  
  23. For 3VZ-E engines, install the front differential bolts. Tighten the bolt holding the carrier cover to the frame to 108 ft. lbs. (147 Nm); tighten the others to 123 ft. lbs. (167 Nm).
  24.  
  25. Install the exhaust pipe. For 3VZ-E engines, tighten the manifold bolts to 46 ft. lbs. (62 Nm), the bracket to the clutch housing to 29 ft. lbs. (39 Nm) and the exhaust pipe clamp to 14 ft. lbs. (19 Nm). On 22R-E engines , tighten the manifold bolts to 46 ft. lbs. (62 Nm), the upper clutch housing clamp bolt to 14 ft. lbs. (19 Nm), the lower bolt to 51 ft. lbs. (69 Nm) and the clamp bolt to 14 ft. lbs. (19 Nm).
  26.  
  27. Install the clutch cylinder; tighten the bolts to 9 ft. lbs. (12 Nm); on 22R-E, install the lower starter bolt and tighten it to 29 ft. lbs. (39 Nm).
  28.  
  29. Install the propeller shaft dust cover assembly if one was removed.
  30.  
  31. Connect the speedometer cable, reverse light switch and transfer indicator switch wiring.
  32.  
  33. Install the driveshafts.
  34.  
  35. Fill the transmission and the transfer case with the proper amount of oil.
  36.  
  37. Lower the vehicle to the ground.
  38.  
  39. Install the transfer shift lever and secure it with the snapring.
  40.  
  41. Install the transmission shift lever. Lightly grease the lever; align the groove of the shift lever cap and the pin of the case cover. Cover the shift lever cap with a cloth; press down on the cap and rotate the lever clockwise to install the lever.
  42.  
  43. On 3VZ-E engines, move the clamp on the heater hose to the correct location and secure the clamp.
  44.  
  45. Install the retaining bolts in the fan shroud.
  46.  
  47. Connect the negative battery terminal.
  48.  
  49. Test drive the vehicle, operating it in all transmission and drive modes. Check for correct operation, ease of shifting, etc.
  50.  

T100 and Tacoma
RF150

See Figure 6

On vehicles with the RF150 and RF150F transmissions, the engine and transmission are removed as an assembly. Refer to Engine & Engine Overhaul for removal procedures. Separate the transmission from the engine as follows:

  1. Unbolt the rear end plate.
  2.  



Click image to see an enlarged view

Fig. Fig. 6: RF150 manual transmission-T100

  1. Remove the starter.
  2.  
  3. Loosen and remove the transmission mounting bolts from the engine. Pull out the transmission toward the rear.
  4.  
  5. Unbolt the rear engine mounting.
  6.  

To install:
  1. Attach the rear engine mounting bolts, tighten to 18 ft. lbs. (25 Nm).
  2.  
  3. Install the transmission, tighten the engine mounting bolts to 53 ft. lbs. (73 Nm).
  4.  
  5. Install the starter to the engine, tighten to 29 ft. lbs. (39 Nm).
  6.  
  7. Install the rear end and stiffener plates with the mounting bolts, tighten to 27 ft. lbs. (37 Nm).
  8.  
  9. Install the engine and transmission into the vehicle; refer to Engine & Engine Overhaul .
  10.  

RF150F

See Figure 7

  1. Remove the transmission shift lever.
  2.  



Click image to see an enlarged view

Fig. Fig. 7: RF150F manual transmission-T100

  1. Raise the vehicle, then drain the transmission fluid.
  2.  
  3. Remove the front propeller shaft.
  4.  
  5. Remove the rear propeller shaft.
  6.  
  7. Disconnect the speedometer cable.
  8.  
  9. Unplug the back-up light switch and the 4WD position switch connector.
  10.  
  11. Remove the 2 bolts, then slave cylinder.
  12.  
  13. Remove the connection and wire from the starter. Remove the bolt for the starter lower side with the clutch line bracket.
  14.  
  15. Remove the front exhaust pipe, separate the oxygen sensor from the pipe.
  16.  
  17. Remove the starter.
  18.  
  19. Remove the bolts and nuts retaining the rear end and right and left stiffener plates.
  20.  
  21. Unbolt the stabilizer bar.
  22.  
  23. Jack up the transmission slightly.
  24.  
  25. Remove the bolts from the engine rear mounting, then remove the bolts and nuts for the crossmember.
  26.  
  27. Remove the 6 transmission mounting bolts from the engine. Disconnect the wire clamps from the transmission. Pull the transmission down and towards the rear.
  28.  
  29. Remove the 4 bolts and the engine rear mounting.
  30.  
  31. Remove the transfer adapter rear mounting bolts. Pull the transfer case straight up, then remove it from the transmission.
  32.  

Take care not to damage the adapter rear oil seal with the transfer input gear slide.

To install:
  1. Support the transmission and transfer case assembly.
  2.  
  3. Attach the transfer case to the transmission. Tighten the adapter rear mounting bolts 27 ft. lbs. (37 Nm).
  4.  
  5. Place the rear engine mounting bolts in place and tighten to 18 ft. lbs. (25 Nm).
  6.  
  7. Place the transmission/transfer case into position. Attach the wire clamps to the transmission, then tighten the 6 rear engine mounting bolts to 53 ft. lbs. (72 Nm).
  8.  
  9. Install the nuts and bolts for the crossmember, tighten to 70 ft. lbs. (95 Nm).
  10.  
  11. Install the 4 bolts to the rear engine mounting, tighten to 9 ft. lbs. (13 Nm).
  12.  
  13. Install the stabilizer bar.
  14.  
  15. Attach the rear end plate and stiffener plates. Tighten to 27 ft. lbs. (37 Nm).
  16.  
  17. Install the starter, tighten to 29 ft. lbs. (39 Nm).
  18.  
  19. Install the front exhaust pipe with a new gasket, install the oxygen sensor.
  20.  
  21. Attach the slave cylinder, tighten 9 ft. lbs. (12 Nm).
  22.  
  23. Engage the back-up light switch and the 4WD position switch connection.
  24.  
  25. Install the speedometer cable.
  26.  
  27. Install the rear and front propeller shafts.
  28.  
  29. Lower the vehicle, fill the transmission with clean fresh fluid.
  30.  
  31. Install the transfer case and transmission shift levers.
  32.  

W59-2-WHEEL DRIVE

See Figure 8

On vehicles with the W59 transmission, the engine and transmission are removed as an assembly. Refer to Engine & Engine Overhaul for removal procedures. Separate the transmission from the engine as follows:

  1. Remove the transmission with the engine.
  2.  
  3. Unbolt the rear end and stiffener plates.
  4.  
  5. Remove the starter.
  6.  
  7. Remove the transmission mounting bolts from the engine. Pull out the transmission toward the rear.
  8.  
  9. Remove the rear engine mount.
  10.  

To install:
  1. Attach the rear engine mount bolts, tighten to 48 ft. lbs. (65 Nm).
  2.  
  3. Install the transmission. Tighten the mounting bolts to 53 ft. lbs. (73 Nm).
  4.  
  5. Install the starter to the engine, tighten to 29 ft. lbs. (39 Nm).
  6.  
  7. Install the rear end and stiffener plates with the mounting bolts, tighten to 27 ft. lbs. (37 Nm).
  8.  
  9. Install the engine and transmission into the vehicle; refer to Engine & Engine Overhaul .
  10.  

W59-4-WHEEL DRIVE

See Figures 9, 10, 11, 12, 13, 14 and 15

  1. Remove the transmission shift lever.
  2.  
  3. Raise the vehicle, then drain the transmission fluid.
  4.  
  5. Remove the front propeller shaft.
  6.  
  7. Remove the rear propeller shaft.
  8.  
  9. Disconnect the speedometer cable.
  10.  
  11. Disconnect the back-up light switch and the 4WD position switch connector.
  12.  
  13. Remove the slave cylinder.
  14.  
  15. Remove the connection and wire from the starter. Remove the bolt for the starter lower side with the clutch line bracket.
  16.  
  17. Remove the front exhaust pipe.
  18.  
  19. Remove the bolts and nuts retaining the rear end and stiffener plates.
  20.  
  21. If applicable, remove the stabilizer bar.
  22.  
  23. Support the transmission rear side. Remove the bolts from the engine rear mounting. Disconnect the O-ring, then remove the bolts and nuts for the crossmember.
  24.  
  25. Remove the rear mounting.
  26.  
  27. Jack up the transmission slightly, then remove the starter.
  28.  
  29. Remove the 4 transmission mounting bolts from the engine. Pull the transmission down and towards the rear.
  30.  
  31. Remove the transfer adapter rear mounting bolts. Pull the transfer case straight up, then remove it from the transmission.
  32.  

Take care not to damage the adapter rear oil seal with the transfer case input gear slide.

To install:
  1. Support the transmission and transfer case assembly.
  2.  
  3. Attach the transfer case to the transmission. Tighten the adapter rear mounting bolts 17 ft. lbs. (24 Nm).
  4.  
  5. Place the assembly into position, then tighten the 4 rear engine mounting bolts to 53 ft. lbs. (72 Nm).
  6.  
  7. Install the starter and tighten to 29 ft. lbs. (39 Nm).
  8.  
  9. Attach the rear mounting bolts for the engine, tighten to 48 ft. lbs. (65 Nm).
  10.  
  11. Install a new O-ring, then install the nuts and bolts for the crossmember. Tighten to 48 ft. lbs. (65 Nm).
  12.  
  13. Install the rear engine mounting bolts, tighten to 14 ft. lbs. (19 Nm).
  14.  
  15. Attach the rear end plate, tighten to 27 ft. lbs. (37 Nm).
  16.  
  17. Install the front exhaust pipe with a new gasket.
  18.  
  19. Install the starter set bolt, tighten to 29 ft. lbs. (39 Nm).
  20.  
  21. Attach the slave cylinder, tighten 9 ft. lbs. (12 Nm).
  22.  
  23. Engage the back-up light switch and the 4WD position switch connection.
  24.  
  25. Install the speedometer cable.
  26.  
  27. Install the rear and front propeller shafts.
  28.  
  29. Lower the vehicle, fill the transmission with clean fresh fluid.
  30.  
  31. Install the transfer case and transmission shift levers.
  32.  



Click image to see an enlarged view

Fig. Fig. 8: W59 manual transmission-2WD Tacoma with 2RZ-FE engine



Click image to see an enlarged view

Fig. Fig. 9: W59 manual transmission-4WD Tacoma



Click image to see an enlarged view

Fig. Fig. 10: Press down on the shift lever cap and rotate it counterclockwise to remove the transmission shift lever



Click image to see an enlarged view

Fig. Fig. 11: With the aid of a pair of pliers, remove the snapring, then pull out the transfer shift lever



Click image to see an enlarged view

Fig. Fig. 12: The arrows indicate the bolts to be removed from the rear end of the front exhaust pipe and oxygen sensor



Click image to see an enlarged view

Fig. Fig. 13: The crossmember has many bolts retaining it



Click image to see an enlarged view

Fig. Fig. 14: Remove the 4 transmission mounting bolts from the engine



Click image to see an enlarged view

Fig. Fig. 15: For the final step, separate the transfer case from the transmission

 
label.common.footer.alt.autozoneLogo