1. Welcome to Tacoma World!

    You are currently viewing as a guest! To get full-access, you need to register for a FREE account.

    As a registered member, you’ll be able to:
    • Participate in all Tacoma discussion topics
    • Communicate privately with other Tacoma owners from around the world
    • Post your own photos in our Members Gallery
    • Access all special features of the site

Harness connection to remove trans for clutch replacement, 95 4WD 5-speed

Discussion in '1st Gen. Tacomas (1995-2004)' started by RickCendejas, Jul 16, 2015.

  1. Jul 16, 2015 at 12:50 PM
    #1
    RickCendejas

    RickCendejas [OP] Member

    Joined:
    Mar 21, 2013
    Member:
    #100225
    Messages:
    14
    Gender:
    Male
    First Name:
    Rick
    Pittsburg, CA
    Vehicle:
    '95 4x4 XtraCab 2.7L
    Stereo, sunroof, wheels, heavy duty leaf springs, currently replacing motor
    I am trying to remove the manual 5-speed transmission in my 1995 Tacoma 2.7 liter engine. I have everything off but cannot find a plug to separate the harness. Does the harness come off all the way from the top of the engine so that I'll be pulling about three feet of harness with the transmission. Thanks for any help. Is there a place where I can read more about changing the clutch. This is my second ever clutch replacement and my first on my Tacoma.
    Rick
     
  2. Jul 17, 2015 at 1:05 PM
    #2
    Wyoming09

    Wyoming09 Well-Known Member

    Joined:
    Apr 24, 2015
    Member:
    #153833
    Messages:
    6,545
    Gender:
    Male
    New Tripoli Pa
    Vehicle:
    2000 Work truck
    Super Springs
    I always unplugged the switches and sensors .

    Don`t forget the 02 sensor Harness is bolted to the top of the transmission on the right side
     
  3. Jul 17, 2015 at 1:55 PM
    #3
    RickCendejas

    RickCendejas [OP] Member

    Joined:
    Mar 21, 2013
    Member:
    #100225
    Messages:
    14
    Gender:
    Male
    First Name:
    Rick
    Pittsburg, CA
    Vehicle:
    '95 4x4 XtraCab 2.7L
    Stereo, sunroof, wheels, heavy duty leaf springs, currently replacing motor
    Thanks for a response, Wyo. (I was born in Cheyenne). I thought I was all alone with this. I found a YouTube video and a guy with bigger hands than mine did it so I finally played the harness off, pulled the transmission by myself using a 4x4 on top of a Harbor Freight hydraulic jack with some tires along the sides for the tranny to fall on. It actually came out pretty easy but I know I'll never get it in by myself. I'm cleaning everything today with TSP and hot water coming straight from my water heater. Can you (or anybody reading) suggest a good clutch kit that I can find in an auto parts store? Will I really need the alignment tool to install the clutch or can I align it by eye or using a dowel? This clutch didn't last that long so I'm thinking my clutch might be out of adjustment.
     
  4. Jul 17, 2015 at 6:47 PM
    #4
    Wyoming09

    Wyoming09 Well-Known Member

    Joined:
    Apr 24, 2015
    Member:
    #153833
    Messages:
    6,545
    Gender:
    Male
    New Tripoli Pa
    Vehicle:
    2000 Work truck
    Super Springs
    Most clutch kits come with the alignment tool.

    It all depends most of the auto parts store clutches have gone down hill.

    I have had good luck with the Aisin kits The Luk Clutch kits All mine are pretty new right now but I think my next Clutch kit will be a Marlin Crawler one
     
  5. Jul 17, 2015 at 7:44 PM
    #5
    RickCendejas

    RickCendejas [OP] Member

    Joined:
    Mar 21, 2013
    Member:
    #100225
    Messages:
    14
    Gender:
    Male
    First Name:
    Rick
    Pittsburg, CA
    Vehicle:
    '95 4x4 XtraCab 2.7L
    Stereo, sunroof, wheels, heavy duty leaf springs, currently replacing motor
    I went with the Aisin Clutch Kit CKT-051 for $180 and the LuK Flywheel LFW200 for $67. Bought them through Amazon for the free shipping. Now I'm going to be without a truck for a while. What is the best way to get the transmission back into place?
     
  6. Jul 18, 2015 at 3:12 AM
    #6
    Wyoming09

    Wyoming09 Well-Known Member

    Joined:
    Apr 24, 2015
    Member:
    #153833
    Messages:
    6,545
    Gender:
    Male
    New Tripoli Pa
    Vehicle:
    2000 Work truck
    Super Springs
    While I have done it myself alone your best bet is to have at least one helper

    The transmission and transfer case go in as a unit.

    When working alone I used a small ratchet strap over a steel bar across the transmission tunnel just as a safety

    I use two jacks aligned front to back on the vehicle one under the engine the other under the trans.

    Sometimes it takes some raising and lowering things to line things up.

    Once the splines are lined up takes a bit of moving the out put shaft meaning it has to be in gear.

    Never force things it is easy to knock the release bearing off

    It is east to get the transfer case shifter in backwards.

    In my misguided youth I would just lift things up by muscle power alone but that was 40 years ago.
     
    Model 70 likes this.
  7. Jul 18, 2015 at 10:47 AM
    #7
    RickCendejas

    RickCendejas [OP] Member

    Joined:
    Mar 21, 2013
    Member:
    #100225
    Messages:
    14
    Gender:
    Male
    First Name:
    Rick
    Pittsburg, CA
    Vehicle:
    '95 4x4 XtraCab 2.7L
    Stereo, sunroof, wheels, heavy duty leaf springs, currently replacing motor
    Thanks again, Who09. Your advice is golden. I don't know why I did it, but I put the transmission in neutral before I removed the stick shifters. Is that going to be a problem while trying to align by moving the 'output shaft' (is that the last thing on the other (rear) side of the transmission, spinning the flange that accepts the driveshaft?)
     
    Last edited: Jul 19, 2015
  8. Jul 18, 2015 at 11:11 AM
    #8
    Wyoming09

    Wyoming09 Well-Known Member

    Joined:
    Apr 24, 2015
    Member:
    #153833
    Messages:
    6,545
    Gender:
    Male
    New Tripoli Pa
    Vehicle:
    2000 Work truck
    Super Springs
    Itis not hard to move the shift forks and get it in gear.

    Not being in gear you can`t move the input shaft

    Yes the output shaft is the flange in the rear the drive shaft bolts to.

    Were only talking a very small amount just twist it right to left till it slides in.

    If the splines are not lined up no amount of pushing or beating will allow them to engage.

    Another thing if the angle of the engine is not correct the top of the bell housing can hit the floor because you can`t most times see this it tends to drive you crazy.

    That is why two jacks are best to lower and raise the engine and trans separate this is where an extra one or two people can make things so much easier.

    As long as they sort of know what there doing.
     
  9. Jul 19, 2015 at 10:04 AM
    #9
    RickCendejas

    RickCendejas [OP] Member

    Joined:
    Mar 21, 2013
    Member:
    #100225
    Messages:
    14
    Gender:
    Male
    First Name:
    Rick
    Pittsburg, CA
    Vehicle:
    '95 4x4 XtraCab 2.7L
    Stereo, sunroof, wheels, heavy duty leaf springs, currently replacing motor
    As soon as I left the computer yesterday I went to the transmission and turned the output flange. I saw the other splined end turn as I turned the output shaft.
    I've been procrastinating doing a second job to replace the exhaust system. I've had the LC Engineering exhaust still in the box for quite some time so yesterday I pulled the stock exhaust from manifold to tailpipe. The engine sure does flop around without the transmission and exhaust to hold it in place. This might be a big advantage and a transmission installation tip to use that play to point the engine slightly downward toward the rear of the truck for transmission to engine alignment. So if you just remove the catalytic converter you'll have that extra play. I got an email notice today saying the clutch kit and flywheel has been shipped. I also wondering if it might be worth renting a transmission jack. I have a buddy who has offered to help me, but for now there is no big hurry. I'll remove the flywheel and start installing the new exhaust system today. I've got a shopping list too...paint, oil, fluids, hoses, zirks, BrakeKleen...
    What is the best way to hold the flywheel to remove the bolts?
     
  10. Jul 20, 2015 at 4:35 PM
    #10
    trx125

    trx125 Well-Known Member

    Joined:
    Sep 13, 2011
    Member:
    #63446
    Messages:
    323
    Gender:
    Male
    HF transmission jack if worth its weight in gold! I will never change another one with out one. And I have done quite a few on many different style cars and trucks.
     
  11. Jul 20, 2015 at 4:37 PM
    #11
    trx125

    trx125 Well-Known Member

    Joined:
    Sep 13, 2011
    Member:
    #63446
    Messages:
    323
    Gender:
    Male
  12. Jul 21, 2015 at 1:29 AM
    #12
    Wyoming09

    Wyoming09 Well-Known Member

    Joined:
    Apr 24, 2015
    Member:
    #153833
    Messages:
    6,545
    Gender:
    Male
    New Tripoli Pa
    Vehicle:
    2000 Work truck
    Super Springs
    I have only ever used a impact to remove the flywheel bolts.
     
  13. Jul 21, 2015 at 9:02 AM
    #13
    RickCendejas

    RickCendejas [OP] Member

    Joined:
    Mar 21, 2013
    Member:
    #100225
    Messages:
    14
    Gender:
    Male
    First Name:
    Rick
    Pittsburg, CA
    Vehicle:
    '95 4x4 XtraCab 2.7L
    Stereo, sunroof, wheels, heavy duty leaf springs, currently replacing motor
  14. Jul 21, 2015 at 7:42 PM
    #14
    trx125

    trx125 Well-Known Member

    Joined:
    Sep 13, 2011
    Member:
    #63446
    Messages:
    323
    Gender:
    Male
  15. Jul 21, 2015 at 8:39 PM
    #15
    Dustrider

    Dustrider Well-Known Member

    Joined:
    Nov 23, 2011
    Member:
    #67601
    Messages:
    138
    Gender:
    Male
    First Name:
    Dave
    Hillsboro Oregon
    Vehicle:
    98 Tacoma 4x4 2.7
    you might be able to rent an impact from an auto parts store.
    If I remember right the manual says to torque in cross pattern to 19 ft lbs and finish in sequence with 90 degree turn of nut

    I changed out my 4cyl/4x4 clutch with a floor jack and bottle jack on a rough and sloping asphalt driveway in 40F weather by myself (and I am 60 y.o.)
    it requires more patience than brute force
    back and forth back and forth between jacks the get the trans to motor gap even

    I just removed the swivel head on the floor jack and strapped the trans to it with a ratchet strap . then rigged a bottle jack near the front of the motor to adjust the angle
    As the bell housing gets close to the motor , pay attention to the gap and adjust angles to make the gap as near perfectly even as possible .
    just like docking a boat , easy does it
    I found it was easier to dock it at a more radical angle than level
    for the final push I got on my back behind it and used both feet on the transfer case
    instead of trying to spin the trans shaft, I put slight pressure against the spline with one arm pulling on the trans and the other hand turning the flywheel, even though you may see the shaft spin at each end in neutral, that wont happen with the slightest pressure on the input spline shaft

    before removing the bottle jack from the front of the motor and raising the rear, put the mounting bolts in and connect wires while you can get in there, then raise the rear and put on the cross member
     
  16. Jul 21, 2015 at 9:53 PM
    #16
    RickCendejas

    RickCendejas [OP] Member

    Joined:
    Mar 21, 2013
    Member:
    #100225
    Messages:
    14
    Gender:
    Male
    First Name:
    Rick
    Pittsburg, CA
    Vehicle:
    '95 4x4 XtraCab 2.7L
    Stereo, sunroof, wheels, heavy duty leaf springs, currently replacing motor
    More great advice. Thanks Dustrider! And thanks also to trx125 for the air impact link. I actually have a 1/2 impact gun but it is a cheapo and very disappointing to use. In my mind impact guns are like an air compressor, the bigger the better. I had actually looked at the Bostitch because it was rated 18th of the most popular at Amazon.com, but it was only 500 ft/lbs of torque. I know it's twice the price, but I'm looking at the AirCat that puts out almost 1,300 ft/lbs here: http://www.amazon.com/AIRCAT-1150-Killer-Torque-2-Inch/dp/B007WQQ90A/ref=zg_bs_15708671_4
    The flywheel is supposed to be in tomorrow and I'm guilty of not doing anything on the truck today to catch up on yard work and other honey-do's
     
  17. Jul 26, 2015 at 3:20 PM
    #17
    RickCendejas

    RickCendejas [OP] Member

    Joined:
    Mar 21, 2013
    Member:
    #100225
    Messages:
    14
    Gender:
    Male
    First Name:
    Rick
    Pittsburg, CA
    Vehicle:
    '95 4x4 XtraCab 2.7L
    Stereo, sunroof, wheels, heavy duty leaf springs, currently replacing motor
    I would like to thank everyone that helped me through this project. It is finally finished, but not without some issues. The LuK flywheel that I purchased was mis-machined so that when the clutch plate mounted on the alignment pins every bolt hole had to be rotary-filed to elongate the holes toward the pins. I also installed the Flowmaster Exhaust System from LCE Performance and I cannot say enough about the fit and finish from header to tail pipe. I took a few pictures along the way... https://www.flickr.com/photos/organize/?start_tab=new_set
     

Products Discussed in

To Top