Transmission Serial Number

REPAIR INSTRUCTION

PRECAUTION

1. BASIC REPAIR HINT

(a) HINTS ON OPERATIONS

Toyota Pickuptruck

1

Attire

• Always wear a clean uniform.

• A hat and safety shoes must be worn.

2

Vehicle protection

Prepare a grille cover, fender cover, seat cover and floor mat before starting the operation.

3

Safe operation

• When working with 2 or more persons, be sure to check safety for one another.

• When working with the engine running, make sure to provide ventilation for exhaust fumes in the workshop.

• If working on high temperature, high pressure, rotating, moving, or vibrating parts, wear appropriate safety equipment and take extra care not to injure yourself or others.

• When jacking up the vehicle, be sure to support the specified location with a safety stand.

• When lifting up the vehicle, use appropriate safety equipment.

4

Preparation of tools and measuring gauge

Before starting the operation, prepare a tool stand, SST, gauge, oil and parts for replacement.

5

Removal and installation, disassembly and assembly operations

• Diagnose with a thorough understanding of proper procedures and of the reported problem.

• Before removing parts, check the general condition of the assembly and for deformation and damage.

• When the assembly is complicated, take notes. For example, note the total number of electrical connections, bolts, or hoses removed. Add matchmarks to ensure reassembly of components to their original positions. Temporarily mark hoses and their fittings if needed.

• Clean and wash the removed parts if necessary and assemble them after a thorough check.

6

Removed parts

• Place removed parts in a separate box to avoid mixing them up with new parts or

contaminating new parts.

• For non-reusable parts such as gaskets, O-rings, and self-locking nuts, replace them

with new ones as instructed in this manual.

• Retain the removed parts for customer inspection, if requested.

INCORRECT CORRECT

(b) JACKING UP AND SUPPORTING VEHICLE

(1) Care must be taken when jacking up and supporting the vehicle. Be sure to lift and support the vehicle at the proper locations.

(c) PRECOATED PARTS

(1) Precoated parts are bolts and nuts that are coated with a seal lock adhesive at the factory.

(2) If a precoated part is retightened, loosened or moved in any way, it must be recoated with the specified adhesive.

(3) When reusing a precoated part, clean off the old adhesive and dry the part with compressed air. Then apply new seal lock adhesive appropriate to that part.

(4) Some seal lock agents harden slowly. You may have to wait for the seal lock adhesive to harden.

(d) GASKETS

(1) When necessary, use a sealer on gaskets to prevent leaks.

(e) BOLTS, NUTS AND SCREWS

(1) Carefully follow all the specifications for tightening torques. Always use a torque wrench.

(1) When inspecting a fuse, check that the wire of the fuse is not broken.

(2) When replacing fuses, be sure that the new fuse has the correct amperage rating. Do not exceed the rating or use one with a lower rating.

Illustration

Symbol

Part Name

Abbreviation

FUSE

FUSE

N

N

Illustration

Symbol

Part Name

Abbreviation

MEDIUM CURRENT FUSE

M-FUSE

N

N

HIGH CURRENT FUSE

H-FUSE

(0

N

N

FUSIBLE LINK

FL

N

N

CIRCUIT BREAKER

CB

N

N

(1) The removal and installation methods of typical clips used for vehicle body parts are shown in the table below. HINT:

If clips are damaged during a procedure, always replace the damaged clip with a new clip.

Shape (Example)

Illustration

Procedures

1. Remove the clips with a clip remover or pliers.

11 j . 1 r

Ü

1. Remove the clips with a clip remover or screwdriver.

1. Remove the clips with a wide scraper to prevent panel damage.

1. Remove the clips by pushing the center pin through and prying out the shell.

Shape (Example)

Illustration

Procedures

1. Remove the clips by unscrewing the center pin and prying out the shell.

1. Remove the clips by prying out the pin and then prying out the shell.

(1) The removal and installation methods of typical claws used for vehicle body parts are shown in the table below. HINT:

If claws are damaged during a procedure, always replace the damaged claws with new caps or covers.

Shape (Example)

Illustration

Procedures

1. Using a screwdriver, detach the claws and remove the cap or covers.

(i) REMOVAL AND INSTALLATION OF VACUUM HOSES

(1) To disconnect a vacuum hose, pull and twist from the end of the hose. Do not pull from the middle of the hose as this may cause damage.

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(2) When disconnecting vacuum hoses, use tags to identify where they should be reconnected.

(3) After completing any hose related repairs, double check that the vacuum hoses are properly connected. The label under the hood shows the proper layout.

(4) When using a vacuum gauge, never force the hose onto a connector that is too large. If a hose has been stretched, it may leak air. Use a step-down adapter if necessary.

(j) TORQUE WHEN USING TORQUE WRENCH

WITH EXTENSION TOOL

L1 L2

L1 L2

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(1) Use the formula below to calculate special torque values for situations where SST or an extension tool is combined with a torque wrench. Formula: T' = L2 / (L1 + L2) * T

T'

Reading of torque wrench {N*m (kgf*cm, ft.*lbf)}

T

Torque {N*m (kgf*cm, ft.*lbf)}

L1

Length of SST or extension tool {cm (in.)}

L2

Length of torque wrench {cm (in.)}

NOTICE:

If an extension tool or SST is combined with a torque wrench and the wrench is used to tighten to a torque specification in this manual, the actual torque will be excessive and parts will be damaged.

2. FOR VEHICLES EQUIPPED WITH SRS AIRBAG AND FRONT SEAT OUTER BELT ASSEMBLY WITH PRETENSIONER

The TOYOTA TACOMA is equipped with a Supplemental

Restraint System (SRS).

CAUTION:

Failure to carry out the service operations in the correct sequence could cause the SRS to unexpectedly deploy during servicing and lead to serious injury. Furthermore, if a mistake is made when servicing the SRS, it is possible that the SRS may fail to operate properly. Before servicing (including removal or installation of parts, inspection or replacement), be sure to read the following section carefully. (a) GENERAL NOTICE

(1) As malfunctions of the SRS are difficult to confirm, the Diagnostic Trouble Codes (DTCs) become the most important source of information when troubleshooting. When troubleshooting the SRS, always check the DTCs before disconnecting the battery.

(2) Work must be started at least 90 seconds after the ignition switch is turned OFF and after the cable is disconnected from the negative (-) battery terminal.

(The SRS is equipped with a backup power source. If work is started within 90 seconds after turning the ignition switch OFF and disconnecting the cable from the negative (-) battery terminal, the SRS may deploy. When the cable is disconnected from the negative (-) battery terminal, clock and audio system memory is erased. Before starting work, make a note of the settings of each memory system. When work is finished, reset the clock and audio system as before. CAUTION:

Never use a backup power source (battery or other) to avoid erasing system memory. The backup power source may inadvertently power the SRS and cause it to deploy.

(3) Even in cases of a minor collision where the SRS does not deploy, the steering wheel pad, front passenger airbag assembly, front seat side airbag assembly, curtain shield airbag assembly and seat belt pretensioner should be inspected

(4) In minor collisions where the SRS does not deploy, the steering wheel pad, front passenger airbag assembly, front seat side airbag assembly, curtain shield airbag assembly and seat belt pretensioner should be inspected before further use of the vehicle.

(5) Never use SRS parts from another vehicle. When replacing parts, use new parts.

(6) Before repairs, remove the airbag sensor assemblies if impacts are likely to be applied to the sensor during repairs.

(7) Never disassemble and attempt to repair the steering wheel pad, front passenger airbag assembly, side airbag assembly, curtain shield airbag assembly and seat belt pretensioner.

(8) Replace the steering wheel pad, front passenger airbag assembly, front seat side airbag assembly, curtain shield airbag assembly and seat belt pretensioner if: 1) damage has occurred from being dropped, or 2) cracks, dents or other defects in the case, bracket or connector are present.

(9) Do not directly expose the airbag sensor assemblies or airbag assemblies to hot air or flames.

(10)Use an ohmmeter / voltmeter with high impedance (10 kQ/V minimum) for troubleshooting electrical circuits.

(11)Information labels are attached to the SRS components. Follow the instructions on the labels.

(12)After work on the SRS is completed, check the SRS warning light.

(b) SPIRAL CABLE

(1) The steering wheel must be fitted correctly to the steering column with the spiral cable at the neutral position, as cable disconnection and other problems may occur. Refer to the information about correct installation of the steering wheel.

(c) STEERING PAD

(1) Always place a removed or new steering pad surface upward as shown in the illustration. Placing the horn button with the pad surface facing down could cause a serious accident if the airbag inflates. Also, do not place anything on top of the horn button.

(2) Never measure the resistance of the airbag squib. This may cause the airbag to inflate, which could cause serious injury.

(3) Grease or detergents of any kind should not be applied to the horn button.

(4) Store the horn button assembly in an area where the ambient temperature is below 93°C (200°F), the humidity is not high and there is no electrical noise.

When using electric welding anywhere on the vehicle, disconnect the airbag ECU connectors (4 pins). These connectors contain shorting springs. This feature reduces the possibility of the airbag deploying due to currents entering the squib wiring.

When disposing of the vehicle or the horn button assembly by itself, the airbag should be deployed using SST before disposal. Activate the airbag in a safe place away from electrical noise.

(d) FRONT PASSENGER AIRBAG ASSEMBLY

(1) Always place a removed or new front passenger airbag assembly with the pad surface facing upward as shown in the illustration. Placing the airbag assembly with the airbag inflation direction facing down could cause a serious accident if the airbag inflates.

(2) Never measure the resistance of the airbag squib. This may cause the airbag to inflate, which could cause serious injury.

(3) Grease or detergents of any kind should not be applied to the front passenger airbag assembly.

(4) Store the airbag assembly in an area where the ambient temperature is below 93°C (200°F), the humidity is not high and there is no electrical noise.

(5) When using electric welding anywhere on the vehicle, disconnect the airbag ECU connectors (4 pins). These connectors contain shorting springs. This feature reduces the possibility of the airbag deploying due to currents entering the squib wiring.

(6) When disposing of the vehicle or the airbag assembly unit by itself, the airbag should be deployed using SST before disposal. Activate the airbag in a safe place away from electrical noise.

(e) CURTAIN SHIELD AIRBAG ASSEMBLY

(1) Always place a removed or new curtain shield airbag assembly in a clear plastic bag, and keep it in a safe place.

Example:

CORRECT

INCORRECT

Clear Plastic Bag

Y

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