I had a leak start on one of the trans oil lines last week which quickly got worse. I replaced all of the hoses, steel lines, fittings into the trans, fluid, and filter. Everything between the rad and the trans is brand new! It only took from Friday to Sunday, with a long sanity break on Saturday. The most valuable lesson I've learned from this job is the correct way to use a bolt extractor: throw it in the trash before it snaps, grab a tap/thread chaser and drill more of the bolt out instead.
This was the
wettest part of the line (ignore the rust) but I was kind of surprised it was there and not the ones that run along the crossmember up front since they were in
considerably worse shape (ignore the rust).
I had started out on the 'easy' portion - replacing the hoses and steel lines. I started by the rad and worked my way down, remounting the new pipe I went to make it easier. Toyota was not very kind to me, and most of the spring clips in the engine bay were pointing in directions that made it heinous to undo with my hand, let alone reach with a compressor tool or pliers. Once all of the new pipes were in place I cut all of the hoses to fit and double checked the routing with my
diagram.
Dropping the transmission pan itself was kind of awful. I had been spraying PB blaster everywhere on everything for several weeks/months at this point but it was no help. Seven of the bolts along either side had the head come off as soon as I put a 1/4" drive ratchet on it and tried to loosen. Two of the bolts had deteriorated badly enough that the heads crumbled. Fortunately a 9mm took one for the team and tolerated a few hammer blows and the bolts came out.
Here's what the inside of the trans looked like after dropping the pan. Once inside, it was smooth sailing from there, a bit of cleaning all around, a new filter, and several pounds of fipg later the transmission was sealed again. A nice reprieve from the shitshow that was disassembly was making a batch of
magnet soup:
I collected as much of the old fluid as a I was able from the pan and lines and dumped it all into a 5gal bucket, and gave the old lines one last shake to get as much out. I figured even though the bucket isn't a perfect cylinder that sticking it with a ruler was 'close enough' since it had been leaking and I'd spilled anyway. I mathed out 5.87qt which was somewhere in the neighborhood of what was expected. I was able to get around a quart into the trans oil rad and lines. I filled from the top in both directions, through the top of the rad, and down through the hose that connects there. I also tried to put some in the reservoir(?) that seems to run along the passenger side of the main rad that's tapped in between the trans and trans rad on one of the lines, but it mostly filled from the other side. I'm guessing the bit of the system that's along the main rad is to help keep it somewhat pegged to the engine temp/warm it up?
The transmission itself initially took around 3-3.5qt through the fill before dripping through the check and oozing back out of the fill. I wasn't quite sure how to proceed at first being at least 2qt short. Between the imprecise measurement of what I removed and not being 100% certain on what the total capacity was, I decided to just take a deep breath and sat in the drivers seat. I ran the engine for around ~15 seconds or so which I figured was just long enough to pull the oil up out of the pan. I had done some quick Googling prior and the largest capacity I had found was for removing the whole transmission assembly which came in at something like 5.6qt. I thought this was slightly low, and figured it wasn't counting the rad and lines, but who knows. After I turned over the engine the first time, it took another 1.5qt, then I kept repeating the previous until it stopped taking more without instantly dripping.
Fortunately it was a hot day and the ambient temp reading on the sensor was 86 degrees as I began, so the reality of my level was that it was pretty close without warming up the fluid. Unfortunately I misread the range for the temp check procedure and heated it up to around 125 before I realized. In the time it took to lower back down, I relieved some stress/tension by wire wheeling all the rust I could see from where the jack stands were, forward. All in all after a lot of time doing that, I'm pretty satisfied with the structural condition of the frame outside of a few points. It'd be really cool if I could source a new front cross member with the tow points or whatever they're called, and have someone weld that in. I'll also probably need a
SafeTCap on both sides of the of the frame in the blue ART201 section. There's a sizeable hole on the drivers side inner rail on the piece that goes inward toward the engine, but it looks like there's multiple layers of metal so it's not clean through yet. The passenger side is developing a hole on the outer layer. I sprayed the ever loving **** out of everything I could inside and out on, near, and in where I wire brushed with Surface Shield so hopefully that will slow the degradation a bit.
Once the transmission was back in range I cracked the check plug one last time, let out an acceptably small amount of oil and waited for it to stop. I was more or less empty on gas so after some clean up I rolled gingerly down the street to the gas station and gave it a few gallons of 91 as a treat. After which I pulled out onto the main road and went on a nice, calm test ride which also happened to be the first time driving with the sprint booster in

. I drove to work today and am still leak, CEL, noise, bump, groan, pang, whine, grind, thud, and clunk free. I didn't have any of those thing's prior to the line leaks, so that's a success in my book.
Some things that were crucial during this service: Nitrile gloves, shop towels, Fast Orange, the screw on hand pumps for the fluid bottles, the gigantic GearWrench tap/die set I bought years ago and never used, crow feet wrenches (necessary for anything on this truck), and my knockoff mechanic scanner (Launch Diagun, paid for itself the first time I used it 5x over). The scanner also lets you change all the different customization settings, which is pretty handy.
Since I've not encountered a character limit yet, I'm going to continue on with my novel and include what's next. My next planned major service is to address the exhaust headers. They're rusted, the y-pipe is rusted, the cats are rusted, the flanges are rusted. I'm targeting sometime in November to give me some breathing room because it's going to be a doozy. I'm not going to DIY those since it looks like way too much effort at every step of the way, and will gladly pay a shop. Based on some things I noticed during the transmission service, at the time of doing the headers I think I would also have the engine mounts replaced? For the headers it looks like new OEM cats and DT shorties is pricey but probably best option for me from what I can tell? I have the crappy Walker Quietflow or whatever catback from RockAuto right now. I replaced that with the same thing a few months ago without realizing it until install time because the one the previous owner installed disintegrated and I lost the tail pipe. I'm not sure what I'd replace it with going forward, but the current one has already started rusting.
All in all, I'm happy, the truck seems happy, and now I get to start doing fun things like modifying the wiring. I got a HO alternator and 1/0 wiring to support a few things I'd like to do in the long term. In the short term I think I'm going to hit all the speakers. The sub blew ~2 months ago and I went without music, but just
fixed it last weekend and now a door speaker is rattling. I have an aftermarket JVC headunit with Android Auto that I installed and subsequently pulled from my previous car before selling it. I was able to wire that in and retain pretty much everything except proper fade/balance control, however that won't matter once I run new wire for future new speakers/amp. The factory backup cam from 2005 looks SHOCKINGLY similar to the quality of ones from more modern cars when hooked up to a newer screen. Some other minor electrical mods I'd like to do are always hot 12v outlets (w separate toggle) because them not being that bothers me. I'd like to switch the radio over to the retained power circuit. I noticed the power windows stay on after the key is removed, and until the door is opened so I'm confident I can emulate RAP. One of the customization settings my scanner has under the rear power window options is a toggle for a "window up" function on the fob. I enabled it but the window still doesn't go up. I hear something like maybe a relay clicking from somewhere in the rear when I press the fob button while the window is down. I didn't test functionality to see if it did that with the setting disabled, but I haven't had a chance to dig deeper.