Toyota Hilux 2005 factory workshop and repair manual download
Toyota Hilux AN10, AN20 2005-2013 factory workshop and repair manual
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File size is large at 170 Mb with some PDF documents with bookmarks.
Covers the AN10, AN20 Toyota Hilux
Petrol/Gasoline engines:
2.0 L 1TR-FE
2.7 L 2TR-FE
4.0 L 1GR-FE V6
Diesel:
2.5 L 2KD-FTV turbodiesel
2.5 L 2KD-FTV intercooled turbodiesel
3.0 L 1KD-FTV intercooled VNT diesel
**Why Change Transmission Fluid?**
Transmission fluid lubricates, cools, and cleans the components within the transmission. Over time, the fluid breaks down and becomes contaminated, losing its effectiveness. Just like oil in an engine, old or dirty transmission fluid can lead to poor shifting performance, overheating, and ultimately, transmission failure.
**How the Transmission Works:**
The transmission takes the engine's power and converts it into motion for the wheels. It uses a series of gears to determine how much power is sent to the wheels based on speed and load. Transmission fluid circulates through the system to ensure smooth operation and to prevent wear.
**What Can Go Wrong?**
- **Contaminated Fluid:** Dirt and debris can build up, causing friction and wear.
- **Overheating:** Old fluid can’t cool effectively, leading to overheating and damage.
- **Poor Shifting:** Slipping or delayed shifts can occur with degraded fluid.
### **Components Needed for Fluid Change**
1. **Transmission Fluid:**
- Check the owner’s manual for the correct type and quantity (typically ATF - Automatic Transmission Fluid).
2. **Transmission Pan Gasket:**
- Prevents leaks when reassembling; it’s often rubber or cork.
3. **Transmission Filter:**
- Catches debris and contaminants. Not all transmissions have them, but if yours does, replace it.
4. **Tools:**
- Socket wrench set
- Screwdrivers (flathead and Phillips)
- Oil catch pan
- Funnel
- Torque wrench
- Rags for cleaning
1. **Preparation:**
- Park the vehicle on a level surface and engage the parking brake.
- Gather all tools and materials.
2. **Drain the Old Fluid:**
- Place the oil catch pan under the transmission pan.
- Remove the bolts securing the transmission pan (usually 10mm).
- Carefully lower the pan; fluid will begin to drain. Allow it to drain completely.
3. **Replace the Filter (if applicable):**
- If your Hilux has a filter, locate it (often attached to the valve body).
- Remove the old filter (may have screws or clips).
- Install the new filter according to the manufacturer’s instructions.
4. **Clean the Transmission Pan:**
- Scrape off old gasket material from the pan and the transmission housing.
- Clean the pan with a degreaser and rags.
5. **Install New Gasket:**
- Place the new gasket on the transmission pan. Ensure it’s seated properly.
6. **Reattach the Transmission Pan:**
- Align the pan with bolt holes and secure it with bolts. Use a torque wrench to tighten to specified torque (usually found in the service manual) in a criss-cross pattern to ensure even pressure.
7. **Refill with New Fluid:**
- Locate the transmission dipstick tube (often marked).
- Insert a funnel into the tube and pour in the new transmission fluid as per the specified capacity in the owner’s manual.
8. **Check Fluid Level:**
- Start the engine and let it idle for a few minutes.
- With the engine running, shift through all gears, then return to 'Park'.
- Check the fluid level using the dipstick; add fluid if necessary.
9. **Clean Up:**
- Dispose of old fluid and materials properly.
- Clean any spills and ensure tools are stored away.
### **Final Advice**
- Monitor for leaks after the fluid change.
- Regular fluid changes can help prolong the life of your transmission.
- Consult your owner’s manual for specific intervals and fluid types.
By following these steps, you will successfully change the transmission fluid in your Toyota Hilux, helping maintain optimal performance and prolonging the life of your vehicle’s transmission. rteeqp73
#### Safety Precautions:
1. **Work on a Flat Surface:** Ensure that the vehicle is on a level surface.
2. **Use Jack Stands:** Never rely solely on a jack to support the vehicle.
3. **Wear Safety Gear:** Always wear gloves and safety glasses.
4. **Disconnect Battery:** If replacing electronic components, disconnect the battery to prevent any electrical issues.
5. **Be Cautious with Springs:** Use spring compressors to safely handle coil springs.
### Step-by-Step Procedure:
#### Step 1: Lift the Vehicle
- **Use the Jack:** Position the jack under the vehicle's jacking point and lift it.
- **Install Jack Stands:** Place jack stands under the vehicle for safety.
#### Step 2: Remove the Wheel
- **Loosen Lug Nuts:** Use the appropriate socket and wrench to slightly loosen the lug nuts while the wheel is still on the ground.
- **Remove the Wheel:** Fully remove the lug nuts and take off the wheel.
#### Step 3: Inspect Suspension Components
- **Check for Damage:** Look for worn bushings, leaking shock absorbers, or broken components.
#### Step 4: Remove Old Suspension Components
1. **Shock Absorbers:**
- Locate the top and bottom mounting bolts.
- Use a socket and wrench to remove both bolts.
- Pull the shock absorber out.
2. **Coil Springs:**
- Use spring compressors on the coil spring to safely compress it.
- Remove the upper mounting bolt and lower control arm bolt.
- Carefully release the spring compressors and remove the spring.
3. **Control Arms:**
- Remove the bolts securing the control arm to the frame and the steering knuckle.
- Use a hammer if necessary to free stuck components.
#### Step 5: Install New Suspension Components
1. **New Shock Absorbers:**
- Position the new shock in place and install the top and bottom bolts.
- Torque to manufacturer specifications (usually specified in service manual).
2. **New Coil Springs:**
- Install the coil spring into its seat.
- Use spring compressors to compress the spring if necessary.
- Secure the upper and lower bolts.
3. **New Control Arms (if applicable):**
- Install the new control arms in reverse order of removal.
- Ensure all bolts are torqued to specifications.
#### Step 6: Reinstall the Wheel
- **Position the Wheel:** Place the wheel back onto the hub.
- **Hand-Tighten Lug Nuts:** Tighten them by hand before lowering the vehicle.
#### Step 7: Lower the Vehicle
- **Remove Jack Stands:** Ensure that no tools or parts are under the vehicle.
- **Lower the Jack:** Carefully lower the vehicle back to the ground.
#### Step 8: Final Checks
- **Tighten Lug Nuts:** Use a torque wrench to tighten the lug nuts to the manufacturer's specifications.
- **Recheck Suspension:** Inspect all installed components to ensure they are secured and correctly positioned.
### Common Pitfalls to Avoid
- **Improper Torque:** Always torque bolts to specifications; failure to do so can lead to component failure.
- **Neglecting Safety:** Always use jack stands and proper gear to avoid injury.
- **Ignoring Alignment:** After suspension work, an alignment is crucial to ensure even tire wear and proper handling.
- **Not Using Spring Compressors:** Handling springs without proper tools can lead to serious injury.
### Replacement Parts
- Ensure to replace worn components with OEM or high-quality aftermarket parts.
- Consider replacing related parts (e.g., bushings and mounts) when replacing shocks or springs.
### Conclusion
Suspension repair on a Toyota Hilux requires careful attention to detail and safety. Follow the steps meticulously and double-check your work to ensure a successful repair. rteeqp73
### Tools Needed for Strut Replacement on a Toyota Hilux
- **Jack and Jack Stands**
- **Use**: To lift the vehicle safely and hold it in place while you work.
- **How to Use**:
- Position the jack under the vehicle's jacking points.
- Pump the jack handle to lift the vehicle.
- Once lifted, place jack stands under solid support points and lower the jack to rest the vehicle on the stands.
- **Lug Wrench**
- **Use**: To remove the wheel lug nuts.
- **How to Use**:
- Place the lug wrench onto the lug nut and turn counterclockwise to loosen.
- Remove all lug nuts and take off the wheel.
- **Socket Set (including a 14mm, 17mm, and 19mm socket)**
- **Use**: To remove strut bolts and other fasteners.
- **How to Use**:
- Select the appropriate socket and attach it to a ratchet.
- Fit the socket over the bolt and turn counterclockwise to remove.
- **Torque Wrench**
- **Use**: To ensure bolts are tightened to the manufacturer’s specifications.
- **How to Use**:
- Set the torque wrench to the specified torque value.
- Use it like a regular ratchet, but it will click when the desired torque is reached.
- **Pry Bar**
- **Use**: To help remove the strut if it is stuck.
- **How to Use**:
- Insert the pry bar between the strut and the suspension components and apply leverage to free the strut.
- **Spring Compressor (if replacing struts with springs)**
- **Use**: To safely compress the coil spring for removal and installation.
- **How to Use**:
- Attach the spring compressor to the coil spring and tighten it evenly until the spring is compressed. This allows for safe removal.
### Steps for Strut Replacement
- **Prepare the Vehicle**
- Park the Hilux on a flat surface and engage the parking brake.
- **Remove the Wheel**
- Use the lug wrench to remove the lug nuts and take off the wheel to access the strut.
- **Disconnect the Strut**
- Remove the bolts securing the strut to the steering knuckle using the socket set. Ensure you have a good grip while loosening them.
- **Remove Top Strut Mounting Bolts**
- Open the hood and locate the strut mounting bolts at the top of the strut tower. Use the socket set to remove these bolts.
- **Extract the Strut**
- If the strut is stuck, use the pry bar to help free it from the lower mount. Carefully pull the strut out from the top.
- **Install the New Strut**
- Align the new strut in the same position as the old one, inserting it into the strut tower first, then into the steering knuckle.
- **Secure the Strut**
- Tighten the top mounting bolts and the lower bolts using the torque wrench to ensure they are at the correct specifications.
- **Reattach the Wheel**
- Put the wheel back on and hand-tighten the lug nuts.
- **Lower the Vehicle**
- Remove the jack stands and lower the vehicle using the jack.
- **Tighten Lug Nuts**
- Once the vehicle is on the ground, use the lug wrench to fully tighten the lug nuts in a star pattern.
### Replacement Parts
- **Struts**
- **Why Replace**: Worn struts can lead to poor handling, increased stopping distances, and a rough ride.
- **Recommendation**: OEM or high-quality aftermarket struts that match your Hilux specifications.
- **Mounts and Bushings**
- **Why Replace**: Often, the strut mounts and bushings can wear out along with the strut. Replacing them ensures optimal performance and prevents future issues.
- **Recommendation**: OEM or high-quality aftermarket mounts.
### Safety Tips
- Always use jack stands when working under the vehicle.
- Wear safety glasses and gloves to protect yourself.
- Ensure the area is clear of obstacles and distractions while working. rteeqp73