Toyota Tundra 2001-06

Transmission Removal & Installation

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  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Disconnect negative battery cable.
  4.  
  5. Remove the shift lever knob subassembly.
  6.  
  7. Remove the four bolts and the shift lever lock boot retainer. Remove the shift lever boot.
  8.  
  9. To remove the floor shift lever assembly, turn over the dust boot. Press down on the shift lever cap and turn it counterclockwise. Pull out the shift lever.
  10.  
  11. Remove the number one engine under cover subassembly. Drain the transmission.
  12.  
  13. Remove the front exhaust pipe. Remove the driveshaft along with the center bearing assembly.
  14.  
  15. Remove the manifold stay. Remove the starter.
  16.  
  17. Remove the number one clutch housing cover. Remove the clutch release cylinder assembly. Remove the clutch accumulator assembly.
  18.  
  19. Properly support the transmission assembly, using the proper transmission jack.
  20.  
  21. Remove the four set bolts of the engine rear mounting on the crossmember. Remove the four nuts, washers, bolts and crossmember.
  22.  
  23. Remove the four bolts and the engine rear mounting insulator.
  24.  
  25. Remove the two bolts, nuts and stabilizer bar brackets.
  26.  
  27. Tilt the transmission assembly downward. Disconnect the speedometer sensor connector. Disconnect the backup light switch connector. Disconnect the wiring harness.
  28.  
  29. Remove the nine transmission retaining bolts. Separate and remove the transmission from the engine.
  30.  

To install:

  1. Installation is the reverse of the removal procedure.
  2.  
  3. Tighten the five upper transmission to engine retaining bolts to 53 ft. lbs. Tighten the four lower transmission to engine retaining bolts to 27 ft. lbs.
    NOTE
    Fifth upper bolt is located on the lower side of the transmission that has three bolt holes.

  4.  
  5. Tighten the crossmember bolts to 53 ft. lbs. Tighten the engine rear mounting set bolts to 13 ft. lbs.
  6.  
  7. Be sure to fill the transmission with the proper grade and type fluid.
  8.  
  9. Start the engine and check for leaks.
  10.  
  11. Roadtest the vehicle.
  12.  

2-Wheel Drive



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

    Negative battery cable
     

  4.  
  5. Drain the transmission oil.
  6.  
  7. Remove the shift lever assembly, as follows:

    Shift lever knob
     
    4 screws, shift lever boot retainer and shift lever boot
     
    6 bolts, shift lever assembly and baffle
     
    Turn over the dust boot
     
    Shift lever cap, cover it with a cloth
     
    Shift lever cap by pressing downward and rotating it counterclockwise
     
    Shift lever
     

  8.  
  9. Remove or disconnect the following:

    Driveshaft
     
    Vehicle Speed Sensor (VSS) and the back-up light switch connectors
     
    Oxygen (O2) sensor connector
     
    Front exhaust pipe from the exhaust manifold and catalytic converter
     
    Clutch release cylinder
     
    Starter wires
     
    Starter
     

  10.  
  11. Position a jack and wooden block under the transmission.
  12.  
  13. Remove or disconnect the following:

    Rear endplate
     
    Rear engine mount bracket
     
    Crossmember
     

  14.  
  15. Attach a engine hoist to the engine hangers.
  16.  
  17. Remove or disconnect the following:

    Engine mounts
     
    Engine/transmission assembly out of the vehicle
     

  18.  
  19. Safely support the engine/transmission assembly.
  20.  
  21. Remove or disconnect the following:

    Transmission-to-engine bolts
     
    Transmission mount
     

  22.  


    Click image to see an enlarged view

    Fig. Removing the transfer shift lever


To install:

  1. Install or connect the following:

    Transmission
     
    Transmission mount. Tighten the 4 bolts to 48 ft. lbs. (65 Nm).
     
    Tighten the 6 transmission-to-engine bolts to 53 ft. lbs. (72 Nm).
     
    Crossmember. Torque the bolts to 53 ft. lbs. (72 Nm).
     
    Rear engine mount-to-crossmember bolts to 13 ft. lbs. (18 Nm).
     
    Starter. Tighten the 2 bolts to 29 ft. lbs. (39 Nm).
     
    Rear endplate. Tighten the 4 bolts to 27 ft. lbs. (37 Nm).
     

  2.  
  3. Install or connect the following:

    Tighten the engine mounts to 28 ft. lbs. (38 Nm).
     
    Starter wires
     
    Clutch release cylinder
     
    Driveshaft
     
    Front exhaust pipe. Tighten the exhaust pipe-to-manifold bolts to 46 ft. lbs. (62 Nm) and the exhaust pipe-to-catalytic converter bolts to 35 ft. lbs. (48 Nm).
     
    Remaining components
     
    Negative battery cable
     

  4.  
  5. Install the shift lever assembly, as follows:

    Shift lever
     
    Shift lever cap, cover it with a cloth
     
    Shift lever cap by pressing downward and rotating it clockwise
     
    Turn over the dust boot
     
    6 bolts, shift lever assembly and baffle
     
    4 screws, shift lever boot retainer and shift lever boot
     
    Shift lever knob
     

  6.  
  7. Fill the transmission with oil.
  8.  
  9. Start the engine and check for leaks.
  10.  
  11. Install the engine undercover.
  12.  
  13. Road test the vehicle and check all fluids.
  14.  

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

    Negative battery cable
     

  4.  
  5. Drain the transmission oil.
  6.  
  7. Remove the shift lever assembly, as follows:

    Shift lever knob
     
    4 screws, shift lever boot retainer and shift lever boot
     
    6 bolts, shift lever assembly and baffle
     
    Turn over the dust boot
     
    Shift lever cap, cover it with a cloth
     
    Shift lever cap by pressing downward and rotating it counterclockwise
     
    Shift lever
     

  8.  
  9. Remove or disconnect the following:

    Driveshaft
     
    Vehicle Speed Sensor (VSS) and the back-up light switch connectors
     
    Oxygen (O 2 ) sensor connector
     
    Front exhaust pipe from the exhaust manifold and catalytic converter
     
    Clutch release cylinder
     
    Starter wires
     
    Starter
     

  10.  
  11. Position a jack and wooden block under the transmission.
  12.  
  13. Remove or disconnect the following:

    Rear endplate
     
    Rear engine mount bracket
     
    Crossmember
     

  14.  
  15. Attach an engine hoist to the engine hangers.
  16.  
  17. Remove or disconnect the following:

    Engine mounts
     
    Engine/transmission assembly out of the vehicle
     

  18.  
  19. Safely support the engine/transmission assembly.
  20.  
  21. Remove or disconnect the following:

    Transmission-to-engine bolts
     
    Transmission mount
     

  22.  

To install:

  1. Install or connect the following:

    Transmission
     
    Transmission mount. Tighten the 4 bolts to 48 ft. lbs. (65 Nm).
     
    Tighten the 6 transmission-to-engine bolts to 53 ft. lbs. (72 Nm).
     
    Crossmember. Torque the bolts to 53 ft. lbs. (72 Nm).
     
    Rear engine mount-to-crossmember bolts to 13 ft. lbs. (18 Nm).
     
    Starter. Tighten the 2 bolts to 29 ft. lbs. (39 Nm).
     
    Rear endplate. Tighten the 4 bolts to 27 ft. lbs. (37 Nm).
     

  2.  
  3. Install or connect the following:

    Tighten the engine mounts to 28 ft. lbs. (38 Nm).
     
    Starter wires
     
    Clutch release cylinder
     
    Driveshaft
     
    Front exhaust pipe. Tighten the exhaust pipe-to-manifold bolts to 46 ft. lbs. (62 Nm) and the exhaust pipe-to-catalytic converter bolts to 35 ft. lbs. (48 Nm).
     
    Remaining components
     
    Negative battery cable
     

  4.  
  5. Install the shift lever assembly, as follows:

    Shift lever
     
    Shift lever cap, cover it with a cloth
     
    Shift lever cap by pressing downward and rotating it clockwise
     
    Turn over the dust boot
     
    6 bolts, shift lever assembly and baffle
     
    4 screws, shift lever boot retainer and shift lever boot
     
    Shift lever knob
     

  6.  
  7. Fill the transmission with oil.
  8.  
  9. Start the engine and check for leaks.
  10.  
  11. Install the engine undercover.
  12.  
  13. Roadtest the vehicle and check all fluids.
  14.  

4-Wheel Drive



  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Disconnect negative battery cable.
  4.  
  5. Remove the transmission shift lever assembly, as follows:

    Shift lever knob
     
    4 screws, shift lever boot retainer and shift lever boot
     
    6 bolts, shift lever assembly and baffle
     
    Turn over the dust boot
     
    Shift lever cap, cover it with a cloth
     
    Shift lever cap by pressing downward and rotating it counterclockwise
     
    Shift lever
     
    Transfer shift lever, using snapring pliers to pull it from the transfer case
     

  6.  
  7. Drain the transmission and the transfer oil.
  8.  
  9. Remove or disconnect the following:

    Driveshafts
     
    Vehicle Speed Sensor (VSS), back-up light switch connector and the transfer indicator switch connector
     
    Clutch release cylinder, move it aside without disconnecting the clutch line
     
    Oxygen (O2) sensor
     
    Front exhaust pipe bracket
     
    Starter
     
    Rear endplate by removing the nuts and 2 bolts
     

  10.  
  11. Using a transmission jack, support the transmission.
  12.  
  13. Remove or disconnect the following:

    4 engine rear mount bolts
     
    8 bolts and the frame crossmember from the side frame
     
    6 transmission-to-engine bolts
     
    3 wire clamps from the transmission
     
    Transmission with the transfer case
     
    4 engine rear mount bolts from the transfer case
     
    Transfer adapter rear mount bolts
     
    Transfer case from the transmission
     

  14.  

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:

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

  4.  


WARNING
Be careful not to damage the oil seal by the input gear spline when installing the transfer.



Engine rear mounting. Tighten the 4 bolts to 48 ft. lbs. (65 Nm).
 
Transmission/transfer case assembly
 

  1. 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.
  2.  
  3. Install or connect the following:

    Tighten the engine-to-transmission bolts to 53 ft. lbs. (72 Nm).
     
    Crossmember. Tighten the 4 bolts to 53 ft. lbs. (72 Nm) and the 4 engine rear mount bolts to 13 ft. lbs. (18 Nm).
     
    Stabilizer bar
     
    Rear endplate Tighten the 2 bolts and nuts to 27 ft. lbs. (37 Nm).
     
    Starter. Tighten the bolts to 29 ft. lbs. (39 Nm).
     
    Front exhaust pipe. Tighten the manifold bolts to 46 ft. lbs. (62 Nm) and the converter bolts to 35 ft. lbs. (48 Nm).
     
    Clutch release cylinder. Tighten the bolts to 9 ft. lbs. (12 Nm).
     
    Driveshafts
     
    Remaining components
     

  4.  
  5. Install the transmission shift lever assembly, as follows:

    Apply MP grease to the shift lever
     
    Shift lever
     
    Shift lever cap, cover it with a cloth
     
    Shift lever cap by pressing downward and rotating it clockwise
     
    Turn over the dust boot
     
    6 bolts, shift lever assembly and baffle
     
    4 screws, shift lever boot retainer and shift lever boot
     
    Shift lever knob
     

  6.  
  7. Connect the negative battery cable.
  8.  
  9. Start the engine and check for leaks.
  10.  
  11. Road test the vehicle for proper operation. Recheck all fluid levels.
  12.  

  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Disconnect negative battery cable.
  4.  
  5. Remove the transmission shift lever assembly, as follows:

    Shift lever knob
     
    4 screws, shift lever boot retainer and shift lever boot
     
    6 bolts, shift lever assembly and baffle
     
    Turn over the dust boot
     
    Shift lever cap, cover it with a cloth
     
    Shift lever cap by pressing downward and rotating it counterclockwise
     
    Shift lever
     
    Transfer shift lever, using snapring pliers to pull it from the transfer case
     

  6.  
  7. Drain the transmission and the transfer oil.
  8.  
  9. Remove or disconnect the following:

    Driveshafts
     
    Vehicle Speed Sensor (VSS), back-up light switch connector and the transfer indicator switch connector
     
    Clutch release cylinder, move it aside without disconnecting the clutch line
     
    Oxygen (O 2 ) sensor
     
    Front exhaust pipe bracket
     
    Starter
     
    Rear endplate by removing the nuts and 2 bolts
     

  10.  
  11. Using a transmission jack, support the transmission.
  12.  
  13. Remove or disconnect the following:

    4 engine rear mount bolts
     
    8 bolts and the frame crossmember from the side frame
     
    6 transmission-to-engine bolts
     
    3 wire clamps from the transmission
     
    Transmission with the transfer case
     
    4 engine rear mount bolts from the transfer case
     
    Transfer adapter rear mount bolts
     
    Transfer case from the transmission
     

  14.  

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:
    WARNING
    Be careful not to damage the oil seal by the input gear spline when installing the transfer.



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



    Engine rear mounting. Tighten the 4 bolts to 48 ft. lbs. (65 Nm).
     
    Transmission/transfer case assembly
     

  4.  
  5. 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.
  6.  
  7. Install or connect the following:

    Tighten the engine-to-transmission bolts to 53 ft. lbs. (72 Nm).
     
    Crossmember. Tighten the 4 bolts to 53 ft. lbs. (72 Nm) and the 4 engine rear mount bolts to 13 ft. lbs. (18 Nm).
     
    Stabilizer bar
     
    Rear endplate Tighten the 2 bolts and nuts to 27 ft. lbs. (37 Nm).
     
    Starter. Tighten the bolts to 29 ft. lbs. (39 Nm).
     
    Front exhaust pipe. Tighten the manifold bolts to 46 ft. lbs. (62 Nm) and the converter bolts to 35 ft. lbs. (48 Nm).
     
    Clutch release cylinder. Tighten the bolts to 9 ft. lbs. (12 Nm).
     
    Driveshafts
     
    Remaining components
     

  8.  
  9. Install the transmission shift lever assembly, as follows:

    Apply MP grease to the shift lever
     
    Shift lever
     
    Shift lever cap, cover it with a cloth
     
    Shift lever cap by pressing downward and rotating it clockwise
     
    Turn over the dust boot
     
    6 bolts, shift lever assembly and baffle
     
    4 screws, shift lever boot retainer and shift lever boot
     
    Shift lever knob
     

  10.  
  11. Connect the negative battery cable.
  12.  
  13. Start the engine and check for leaks.
  14.  
  15. Roadtest the vehicle for proper operation. Recheck all fluid levels.
  16.  

 
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