Toyota Pick-ups, Land Cruiser, and 4 Runner 1997-00

Transmission Assembly

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REMOVAL & INSTALLATION



W59 Transmission
EXCEPT 4RUNNER
  1. Remove the front console box.
  2.  
  3. Detach the four screws, shift lever boot and retainer.
  4.  
  5. Cover the shift lever cap with a cloth.
  6.  
  7. Depressing down on the shift lever cap and rotate it counterclockwise to remove.
  8.  
  9. Pull out the shift lever.
  10.  
  11. Remove transfer shift lever.
  12.  
  13. Use pliers to remove the snap ring and pull out the shift lever.
  14.  
  15. Raise vehicle and drain transmission oil.
  16.  
  17. Remove No. 1 and No. 2 engine undercovers
  18.  
  19. Disconnect the front and rear propeller shafts
  20.  
  21. Detach the vehicle speed sensor, back-up light switch and 4WD position switch connectors.
  22.  
  23. If your vehicle has an Antilock Braking System (ABS) and/or a differential lock, detach the connector from the switch.
  24.  
  25. Remove the two bolts and disconnect the clutch release cylinder.
  26.  
  27. Detach the front exhaust pipe.
  28.  
  29. Remove the ring, and remove the two bolts and support bracket.
  30.  
  31. Detach the two nuts, oxygen sensor and gasket.
  32.  
  33. Detach the two set bolts of the front exhaust pipe bracket.
  34.  
  35. Remove the three nuts, front exhaust pipe and two gaskets.
  36.  
  37. Remove the four bolts, two nuts and rear end plate.
  38.  
  39. Support the rear of the transmission.
  40.  
  41. Remove the four set bolts of the engine rear mounting.
  42.  
  43. Remove the mounting bracket from the rear of the engine.
  44.  
  45. Remove the four bolts and engine rear mounting from the transmission.
  46.  
  47. Lift the transmission slightly.
  48.  
  49. Support the transmission using a suitable device.
  50.  
  51. Remove the set bolt of the starter on the lower side with the clutch line bracket.
  52.  
  53. Detach the connector and wire, and remove the set bolt of the starter on the upper side and starter.
  54.  
  55. Remove the transmission with transfer case.
  56.  
  57. Disconnect the wire harness from the transmission.
  58.  
  59. Remove the three transmission mounting bolts from the engine.
  60.  
  61. Pull out the transmission.
  62.  

Remove the transmission with the transfer case down and toward the rear.

  1. Separate the transfer case from the transmission.
  2.  
  3. Disconnect the breather hose
  4.  
  5. Remove the eight transfer case adapter rear mounting bolts.
  6.  
  7. Lift the transfer case straight up and remove it from the transmission.
  8.  
  9. Installation is the reverse of removal.
  10.  

W59 and R150 Transmissions
4RUNNER
  1. Disconnect the negative battery cable from the battery.
  2.  
  3. Remove the transmission shift lever from the inside of the vehicle, as follows:
    1. Remove the four screws and front console box.
    2.  
    3. Remove the screws holding the shift lever boot retainer and remove the shift lever boot.
    4.  
    5. Cover the shift lever cap with a cloth. Pressing down on the shift lever cap, rotate it counterclockwise to remove it.
    6.  

  4.  
  5. On 4WD models, remove the transfer shift lever from the inside of the vehicle. Using snap ring pliers, remove the snap ring and pull out the shift lever from the transfer case.
  6.  
  7. Raise the vehicle and drain the transmission and the transfer oil.
  8.  
  9. Remove the No. 1 and No. 2 engine undercover.
  10.  
  11. Disconnect the front and rear driveshafts.
  12.  
  13. Detach the vehicle speed sensor, back-up light switch, and the 4WD position switch connectors.
  14.  
  15. If equipped with ABS and/or differential lock: Detach the "L4" position switch connector.
  16.  
  17. Remove the two bolts holding the clutch release cylinder and lay it along side the engine. Do NOT disconnect the clutch line.
  18.  
  19. Remove the exhaust pipe bracket.
  20.  
  21. Remove the rear end plate by removing the nuts and two bolts.
  22.  
  23. Remove the crossmember.
    1. Support the transmission rear side.
    2.  
    3. Remove the four bolts from the engine rear mounting.
    4.  
    5. Remove the four bolts, nuts and the crossmember.
    6.  

  24.  
  25. Remove the four bolts and the engine rear mounting from the transfer case.
  26.  
  27. Using a transmission jack, support the transmission.
  28.  
  29. Detach the wiring and the connector and remove the starter.
  30.  
  31. Disconnect the wiring harness from the transmission.
  32.  
  33. Remove the transmission mounting bolts from the engine and lower the transmission with the transfer case (on 4WD models) down and to the rear.
  34.  
  35. If equipped, remove the transfer case from the transmission.
  36.  

To install:

  1. If applicable, install the transfer case to the transmission. Tighten the bolts to 17 ft. lbs. (24 Nm). Be careful not to damage the oil seal by the input gear spline when installing the transfer.
  2.  
  3. Place the transmission with the transfer case (4WD models) at the installation position.
  4.  
  5. Support the transmission with a jack. Align the input shaft spline with the clutch disc, and push the transmission with the transfer case fully into position.
  6.  
  7. Install the engine to transmission bolts and tighten the bolts to 53 ft. lbs. (72 Nm)
  8.  
  9. Install the starter by installing the two bolts and connecting the electrical wiring. Tighten the two bolts to 29 ft. lbs. (39 Nm).
  10.  
  11. Install the engine rear mounting and tighten the four bolts to 48 ft. lbs. (65 Nm).
  12.  
  13. Raise the transmission slightly with a jack.
  14.  
  15. Install the crossmember and tighten the four bolts to 48 ft. lbs. (65 Nm).
  16.  
  17. Lower the transmission and transfer.
  18.  
  19. Install the remaining components in the reverse of the removal procedure and tighten the retainers as follows:

    Four engine rear mounting bolts: 14 ft. lbs. (19 Nm)
     
    Rear end plate bolts: to 27 ft. lbs. (37 Nm)
     
    Front exhaust pipe bracket bolts: 52 ft. lbs. (71 Nm)
     
    Exhaust pipe-to-catalytic converter bolts: 35 ft. lbs. (48 Nm)
     
    Support bracket bolts: 14 ft. lbs. (19 Nm)
     
    Clutch release cylinder bolts: 108 inch lbs. (13 Nm)
     

  20.  
  21. Connect the negative battery cable, start the engine, and check for leaks.
  22.  
  23. Road test the vehicle for proper operation and recheck all the fluid levels.
  24.  

R150 and R150F Transmission
2WD T100 MODELS

On these models, the transmission is removed with the engine.

  1. Turn the ignition switch OFF . Disconnect the battery cables, negative cable first.
  2.  
  3. Matchmark the hood hinges and remove the hood.
  4.  
  5. Remove the battery and battery tray.
  6.  
  7. Drain the engine oil, transmission oil and cooling system.
  8.  
  9. Remove the expansion tank.
  10.  
  11. Remove the radiator.
  12.  
  13. Remove the air cleaner cap, Mass Air Flow (MAF) meter and resonator. Remove the air cleaner case.
  14.  
  15. Disconnect the accelerator cable from the throttle body.
  16.  
  17. Remove the intake air connector.
  18.  
  19. If equipped with air conditioning, remove the air conditioning compressor and bracket. Position the compressor aside with the air conditioning lines attached.
  20.  
  21. Disconnect the heater hoses at the cowl panel.
  22.  
  23. Disconnect the following hoses:

    Brake booster vacuum hose
     
    Evaporator (EVAP) canister purge hose
     
    Two power steering hoses
     
    Fuel return hose
     
    Fuel inlet hose
     

  24.  
  25. Remove the power steering pump.
  26.  
  27. Disconnect the alternator wires from the alternator.
  28.  
  29. Disconnect the Engine Control Module (ECM) wiring from the ECM.
  30.  
  31. Disengage the engine wiring harness and connectors from the vehicle as follows:
    1. Disengage the igniter connector.
    2.  
    3. Disconnect the ground strap from the cowl top panel.
    4.  
    5. Disconnect the four engine wiring harness clamps.
    6.  
    7. Pull out the engine wiring harness from the vehicle.
    8.  

  32.  
  33. Remove the shift lever assembly as follows:
    1. Remove the shift lever knob.
    2.  
    3. Remove the four screws and shift lever boot.
    4.  
    5. Remove the six bolts, shift lever assembly and baffle.
    6.  

  34.  



Click image to see an enlarged view

Fig. Removing the transfer shift leverTacoma, 4Runner and T-100 with R150 and R150F transmissions

  1. Remove the sway bar.
  2.  
  3. Remove the driveshaft from the vehicle.
  4.  
  5. Disconnect the speedometer cable from the transmission.
  6.  
  7. Disconnect the front exhaust pipe from the exhaust manifold and catalytic converter.
  8.  
  9. Remove the clutch release cylinder.
  10.  
  11. Disconnect the wires at the starter.
  12.  
  13. Position a jack and wooden block under the transmission and remove the rear engine-mounting bracket.
  14.  
  15. Attach a suitable engine hoist to the engine hangers.
  16.  
  17. Remove the nuts and bolts from the engine mounts.
  18.  
  19. Carefully lift the engine/transmission assembly out of the vehicle.
  20.  
  21. Safely support the engine/transmission assembly.
  22.  
  23. Remove the rear end plate by removing the nuts and four bolts.
  24.  
  25. Remove the starter by removing the two bolts.
  26.  
  27. Remove the transmission from the engine by removing the six mounting bolts from the engine.
  28.  
  29. Pull out the transmission toward the rear.
  30.  
  31. Remove the transmission mount by removing the four bolts.
  32.  

To install:

  1. Install the transmission mount by installing the four bolts. Tighten the bolts to 18 ft. lbs. (25 Nm).
  2.  
  3. Connect the transmission to the engine by installing the six bolts. Tighten the bolts to 53 ft. lbs. (72 Nm).
  4.  
  5. Install the starter and tighten the two bolts to 29 ft. lbs. (39 Nm).
  6.  
  7. Install the rear end plate and tighten the four nuts and bolts to 27 ft. lbs. (37 Nm).
  8.  
  9. Attach the engine hoist to the engine hangers. Carefully lower the engine/transmission assembly into the vehicle. Keep the engine level, while aligning the engine mounts.
  10.  
  11. Install the engine mount fasteners, but do NOT fully tighten.
  12.  
  13. Position a jack and wooden block under the transmission and install the rear engine-mounting bracket. Tighten the bolts to the frame to 42 ft. lbs. (58 Nm) and the bolts to the mount to 13 ft. lbs. (18 Nm).
  14.  
  15. Remove the jack and engine hoist. Tighten the engine mounts to 28 ft. lbs. (38 Nm).
  16.  
  17. Install the remaining components in the reverse of the removal procedure. Tighten the exhaust pipe-to-manifold bolts to 46 ft. lbs. (62 Nm), the support bracket bolts and the exhaust pipe-to-catalytic converter bolts to 29 ft. lbs. (39 Nm), and the exhaust pipe clamp nuts to 14 ft. lbs. (19 Nm).
  18.  
  19. Fill the engine oil, engine coolant, and transmission oil.
  20.  
  21. Connect the negative and positive cables to the battery.
  22.  
  23. Start the engine and check for leaks.
  24.  
  25. Install the engine undercover. Install the hood.
  26.  
  27. Road test the vehicle and check all fluids.
  28.  

4WD T100 MODELS
  1. Disconnect the negative battery cable from the battery.
  2.  
  3. Remove the transmission shift lever from the inside of the vehicle, as follows:
    1. Remove the four screws and front console box.
    2.  
    3. Remove the screws holding the shift lever boot retainer and remove the shift lever boot.
    4.  
    5. Cover the shift lever cap with a cloth. Pressing down on the shift lever cap, rotate it counterclockwise to remove it.
    6.  

  4.  
  5. Remove the transfer shift lever from the inside of the vehicle. Using snap ring pliers, remove the snap ring and pull out the shift lever from the transfer case.
  6.  
  7. Raise the vehicle and drain the transmission and the transfer oil.
  8.  
  9. Disconnect the driveshafts from the vehicle.
  10.  
  11. Detach the speedometer cable, back-up light switch connector and the transfer indicator switch connector.
  12.  
  13. Remove the two bolts holding the clutch release cylinder and lay it along side the engine. Do NOT disconnect the clutch line.
  14.  
  15. Remove the exhaust pipe bracket.
  16.  
  17. Remove the starter by disconnecting the starter wires and removing the two bolts.
  18.  
  19. Remove the stiffener plate by removing the four bolts.
  20.  
  21. Remove the rear end plate by removing the nuts and two bolts.
  22.  
  23. Remove the stabilizer bar from the suspension.
  24.  
  25. Using a transmission jack, support the transmission.
  26.  
  27. Remove the frame crossmember from the side frame as follows:
    1. Remove the four bolts from the engine rear mounting.
    2.  
    3. Remove the eight bolts and the frame crossmember from the side frame.
    4.  

  28.  
  29. Remove the six transmission mounting bolts from the engine.
  30.  
  31. Disconnect the three wire clamps from the transmission.
  32.  
  33. Remove the transmission with the transfer toward the rear of the vehicle.
  34.  
  35. Remove the four bolts and the engine rear mounting from the transfer case.
  36.  
  37. Remove the transfer adapter rear mounting bolts.
  38.  
  39. Pull the transfer straight up and remove it from the transmission.
  40.  

To install:

  1. Apply multi-purpose grease to the adapter oil seal and shift the two shift fork shafts to the high four position.
  2.  
  3. Install the transfer to the transmission. Install the bolts and tighten the bolts to 27 ft. lbs. (37 Nm). Be careful not to damage the oil seal by the input gear spline when installing the transfer.
  4.  
  5. Install the engine rear mounting and tighten the four bolts to 18 ft. lbs. (25 Nm).
  6.  
  7. Place the transmission with the transfer at the installation position.
  8.  
  9. Support the transmission with a jack. Align the input shaft spline with the clutch disc, and push the transmission with the transfer fully into position.
  10.  
  11. Install the engine to transmission bolts. Tighten the bolts to 53 ft. lbs. (72 Nm)
  12.  
  13. Install the No. 2 frame crossmember, as follows:
    1. Raise the transmission slightly with a jack.
    2.  
    3. Install the No. 2 frame crossmember to the side frame and tighten the eight bolts to 70 ft. lbs. (95 Nm).
    4.  
    5. Lower the transmission and transfer.
    6.  
    7. Install the four mounting bolts to the engine rear mounting and tighten the bolts to 108 inch lbs. (13 Nm).
    8.  

  14.  
  15. Install the stabilizer bar.
  16.  
  17. Install the rear end plate by installing the two bolts and nuts. Tighten to 27 ft. lbs. (37 Nm).
  18.  
  19. Install the stiffener plate with the four bolts. Tighten the bolts to 27 ft. lbs. (37 Nm).
  20.  
  21. Install the remaining components in the reverse order of removal.
  22.  
  23. Install the transmission shift lever, as follows:
    1. Apply MP grease to the transmission shift lever.
    2.  
    3. Align the groove of the shift lever cap and the pin par of the case cover. Cover the shift lever cap with a cloth. Pressing down on the shift lever cap, rotate it clockwise to install.
    4.  
    5. Install shift lever boot retainer with the four screws.
    6.  
    7. Install the front console box with the four screws.
    8.  

  24.  
  25. Connect the negative battery cable. Start the engine and check for leaks.
  26.  
  27. Road test the vehicle for proper operation. Recheck all fluid levels.
  28.  

2WD TACOMA MODELS
  1. Remove the transmission with the engine. For additional information, please refer to the following topic(s): "ENGINE AND ENGINE OVERHAULL," "Engine Removal and Installation." See .
  2.  
  3. Remove the left and right side stiffener plates.
  4.  
  5. Remove the rear end plate.
  6.  
  7. Detach the connector and remove the starter.
  8.  
  9. Place a stand under the transmission.
  10.  
  11. Remove the transmission mounting bolts and pull the transmission toward the rear.
  12.  
  13. Remove the rear engine mount by removing the four bolts.
  14.  

To install:

  1. Install the rear engine mount by installing the four bolts. Tighten the bolts to 48 ft. lbs. (65 Nm).
  2.  
  3. Install the transmission to the engine.
    1. Align the input shaft spline with the clutch disc and install the transmission to the engine. Tighten the three bolts to 53 ft. lbs. (72 Nm).
    2.  

  4.  
  5. Install the starter and tighten the bolts to 29 ft. lbs. (39 Nm). Connect the connectors.
  6.  
  7. Install the rear end plate and tighten the bolts to 27 ft. lbs. (37 Nm).
  8.  
  9. Install the left and right side stiffener plates.
  10.  
  11. Install the transmission with the engine assembly.
  12.  

4WD TACOMA MODELS
  1. Disconnect the negative battery cable from the battery.
  2.  
  3. Remove the transmission shift lever from the inside of the vehicle, as follows:
    1. Remove the four screws and front console box.
    2.  
    3. Remove the screws holding the shift lever boot retainer and remove the shift lever boot.
    4.  
    5. Cover the shift lever cap with a cloth. Pressing down on the shift lever cap, rotate it counterclockwise to remove it.
    6.  

  4.  
  5. Remove the transfer shift lever from the inside of the vehicle. Using snap ring pliers, remove the snap ring and pull out the shift lever from the transfer case.
  6.  
  7. Raise the vehicle and drain the transmission and the transfer oil.
  8.  
  9. Disconnect the front and rear driveshafts.
  10.  
  11. Detach the speedometer cable and the back-up light switch connector.
  12.  
  13. On the standard cab, disconnect the 4WD position switch connector.
  14.  
  15. On the extra cab, disconnect the "L4" position switch connector.
  16.  
  17. Remove the two bolts holding the clutch release cylinder and lay it along side the engine. Do NOT disconnect the clutch line.
  18.  
  19. Remove the exhaust pipe bracket.
  20.  
  21. Remove the starter by disconnecting the starter wires and removing the two bolts.
  22.  
  23. Remove the rear end plate by removing the nuts and two bolts.
  24.  
  25. Remove the crossmember.
    1. Support the transmission rear side.
    2.  
    3. Remove the four bolts from the engine rear mounting.
    4.  
    5. Disconnect the O-ring and remove the four bolts, nuts and the crossmember.
    6.  

  26.  
  27. Using a transmission jack, support the transmission.
  28.  
  29. Remove the six transmission mounting bolts from the engine.
  30.  
  31. Disconnect the three wire clamps from the transmission.
  32.  
  33. Remove the transmission with the transfer toward the rear of the vehicle.
  34.  
  35. Remove the four bolts and the engine rear mounting from the transfer case.
  36.  
  37. Remove the transfer adapter rear mounting bolts.
  38.  
  39. Pull the transfer straight up and remove it from the transmission.
  40.  

To install:

  1. Apply multi-purpose grease to the adapter oil seal and shift the two shift fork shafts to the "H4" position.
  2.  
  3. Install the transfer to the transmission. Install the bolts and tighten the bolts to 17 ft. lbs. (24 Nm). Be careful not to damage the oil seal by the input gear spline when installing the transfer.
  4.  
  5. Place the transmission with the transfer at the installation position.
  6.  
  7. Support the transmission with a jack. Align the input shaft spline with the clutch disc, and push the transmission with the transfer fully into position.
  8.  
  9. Install the engine to transmission bolts. Tighten the bolts to 53 ft. lbs. (72 Nm)
  10.  
  11. Install the engine rear mounting and tighten the four bolts to 48 ft. lbs. (65 Nm).
  12.  
  13. Install the crossmember, as follows:
    1. Raise the transmission slightly with a jack.
    2.  
    3. Install the crossmember and tighten the four bolts to 48 ft. lbs. (65 Nm).
    4.  
    5. Lower the transmission and transfer.
    6.  
    7. Install the remaining components in the reverse of the removal procedure, making sure to note the following tightening specifications:

      Four engine rear mounting bolts: 14 ft. lbs. (19 Nm)
       
      Rear end plate bolts: 13 ft. lbs. (18 Nm) on R150 and R150F transmissions, or to 27 ft. lbs. (37 Nm) on W59 transmissions
       
      Starter bolts: 29 ft. lbs. (39 Nm)
       
      Front exhaust pipe-to-manifold bolts: 46 ft. lbs. (62 Nm)
       
      Exhaust bracket bolts: 33 ft. lbs. (44 Nm)
       
      Exhaust pipe-to-catalytic converter bolts: 35 ft. lbs. (48 Nm)
       
      Clutch release cylinder bolts: 108 inch lbs. (13 Nm)
       

    8.  

  14.  
  15. Refill the transmission to the correct level.
  16.  
  17. Connect the negative battery cable. Start the engine and check for leaks.
  18.  
  19. Road test the vehicle for proper operation. Recheck all fluid levels.
  20.  

 
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