Toyota Tacoma 2002-06

Transmission Removal & Installation

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  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. Remove the upper console rear panel subassembly.
  6.  
  7. Remove the rear console box assembly. Remove the front console box. Remove the shift lever boot assembly. Remove the floor shift lever assembly.
  8.  
  9. Remove the number two engine undercover subassembly.
  10.  
  11. Drain the transmission oil.
  12.  
  13. Remove the front exhaust pipe assembly.
  14.  
  15. Remove the front driveshaft, if equipped.
  16.  
  17. Remove the driveshaft.
    NOTE
    Some vehicles are also equipped with a center bearing assembly, remove if equipped.

  18.  
  19. Remove the starter. Remove the manifold stay.
  20.  
  21. On five speed, separate the clutch release cylinder assembly by removing the two bolts.
  22.  
  23. On six speed, remove the number one clutch housing cover. Remove the clutch release cylinder assembly. Remove the clutch accumulator assembly.
  24.  
  25. Using the proper support equipment, support the transmission (2WD) or transmission/transfer case (4WD).
  26.  
  27. Remove the bolts from the engine rear mounting. Remove the bolts, nuts and frame crossmember number three sub assembly.
  28.  
  29. Remove the bolts and the engine mounting insulator rear number one.
    NOTE
    Be sure that the transmission (2WD) or transmission/transfer case (4WD) is properly supported.

  30.  
  31. Tilt the transmission assembly downward. Disconnect all electrical wires and hoses that will interfere with the removal of the transmission (2WD) or transmission/transfer case (4WD).
    NOTE
    When tilting the transmission assembly downward, make sure that the cooling fan does not hit the radiator fan shroud.

  32.  
  33. Remove the transmission assembly retaining bolts. Remove the transmission (2WD) or transmission/transfer case (4WD) from the vehicle.
    NOTE
    If equipped with 4WD, remove the transmission and the transfer case as one unit.

  34.  
  35. On 4WD separate the transmission from the transfer case as required.
  36.  

To install:

  1. Installation is the reverse of the removal procedure.
  2.  
  3. On five speed, tighten the three upper transmission to engine retaining bolts to 53 ft. lbs. and the four lower bolts to 27 ft. lbs.
  4.  
  5. On five speed, tighten the four upper transmission to engine retaining bolts to 53 ft. lbs. and the five lower bolts to 28 ft. lbs.
  6.  
  7. Be sure to fill the transmission with the proper grade and type oil.
  8.  
  9. Start the engine and check for leaks, correct as required.
  10.  

2-Wheel Drive



  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Remove or disconnect the following:

    Transmission with the engine
     
    Left and right side stiffener plates
     
    Rear end-plate
     
    Starter
     

  4.  
  5. Place a stand under the transmission.
  6.  
  7. Remove or disconnect the following:

    Transmission bolts and pull the transmission rearward
     
    Rear engine mount by removing the 4 bolts
     

  8.  

To install:

  1. Install or connect the following:

    Rear engine mount. Tighten the 4 bolts to 48 ft. lbs. (65 Nm).
     
    Transmission by aligning the input shaft spline with the clutch disc. Tighten the transmission-to-engine bolts to 53 ft. lbs. (72 Nm).
     
    Starter. Tighten the bolts to 29 ft. lbs. (39 Nm).
     
    Rear end-plate. Tighten the bolts to 27 ft. lbs. (37 Nm).
     
    Left and right side stiffener plates
     
    Transmission with the engine assembly.
     

  2.  

4-Wheel Drive



  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Remove or disconnect the following:

    Negative battery cable
     
    4 screws and front console box
     
    Shift lever boot retainer screws and the shift lever boot
     
    Shift lever cap, by pressing downward on the shift lever cap covered with a cloth and rotating it counterclockwise to remove it
     
    Transfer shift lever, using snapring pliers to pull it from the transfer case
     

  4.  
  5. Drain the transmission and the transfer oil.
  6.  
  7. Remove or disconnect the following:

    Front and rear driveshafts
     
    Speedometer cable and the back-up light switch connector
     
    4WD position switch connector, on the Standard cab
     
    L4 position switch connector, on the Extra cab
     
    Clutch release cylinder, by moving it aside without disconnecting the clutch line
     
    Exhaust pipe bracket
     
    Starter
     
    Rear end plate by removing the nuts and 2 bolts
     

  8.  
  9. Support the transmission rear side.
  10.  
  11. Remove or disconnect the following:

    4 engine rear mount bolts
     
    O-ring and the crossmember
     

  12.  
  13. Using a transmission jack, support the transmission.
  14.  
  15. Remove or disconnect the following:

    6 transmission-to-engine bolts
     
    3 wire clamps from the transmission
     
    Transmission with the transfer case
     
    Engine rear mounting from the transfer case
     
    Transfer adapter rear mount bolts
     
    Transfer case from the transmission
     

  16.  

To install:

  1. Apply MP grease to the adapter oil seal and shift the 2 shift fork shafts to the high 4 position.
  2.  
  3. Install or connect the following:
    NOTE
    Be careful not to damage the oil seal by the input gear spline when installing the transfer.



    Transfer to the transmission. Tighten the bolts to 17 ft. lbs. (24 Nm).
     



    Transmission/transfer case assembly, by aligning the input shaft spline with the clutch disc.
     

  4.  
  5. Support the transmission with a jack.
  6.  
  7. Install or connect the following:

    Tighten the engine to transmission bolts to 53 ft. lbs. (72 Nm)
     
    Engine rear mount. Tighten the 4 bolts to 48 ft. lbs. (65 Nm).
     

  8.  
  9. Raise the transmission slightly with a jack.
  10.  
  11. Install or connect the following:

    Crossmember. Tighten the 4 bolts to 48 ft. lbs. (65 Nm).
     
    Engine rear mount. Tighten the bolts to 14 ft. lbs. (19 Nm).
     
    Rear end-plate. Tighten the 4 bolts and nuts to 13 ft. lbs. (18 Nm) on R150 and R150F transmissions or to 27 ft. lbs. (37 Nm) on W59 transmissions.
     
    Starter. Tighten both bolts to 29 ft. lbs. (39 Nm).
     
    Front exhaust pipe. Tighten the exhaust pipe-to-manifold bolts to 46 ft. lbs. (62 Nm), the exhaust bracket bolts to 33 ft. lbs. (44 Nm) and the exhaust pipe-to-catalytic converter bolts to 35 ft. lbs. (48 Nm).
     
    Clutch release cylinder. Tighten the 2 bolts to 108 inch lbs. (13 Nm).
     
    L4 position switch connector on the extra cab or the 4WD position switch connector on the standard cab.
     
    VSS and the back-up light switch connector.
     
    Front and rear driveshafts.
     

  12.  
  13. Refill the transmission to the correct level.
  14.  
  15. Apply MP grease to the transfer shift lever.
  16.  
  17. Install or connect the following:

    Transfer shift lever.
     
    Snapring, using pliers
     

  18.  
  19. 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 4 screws.
    6.  
    7. Install the front console box with the 4 screws.
    8.  

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

 
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