MANUAL TRANSMISSION ASSEMBLY (for 2KD-FTV) REMOVAL


  1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL

  2. DRAIN MANUAL TRANSMISSION OIL


    1. Remove the filler plug and gasket.

    2. Remove the drain plug and gasket, and drain the oil.

    3. Install the drain plug with a new gasket.

      Torque:
      37 N*m  { 377 kgf*cm, 27 ft.*lbf }

  3. REMOVE EXHAUST PIPE ASSEMBLY FRONT (for Long Wheelbase)


    1. Remove the 4 bolts, 2 nuts and 2 compression springs. 2 gasket and exhaust pipe assembly front.

    2. Disconnect the exhaust pipe support, and remove the exhaust pipe assembly front and 2 gaskets.

  4. REMOVE EXHAUST PIPE ASSEMBLY FRONT (for Super Long Wheelbase)


    1. Remove the 4 bolts, 2 nuts, 2 compression springs. exhaust pipe assembly front and 2 gaskets.

    2. Disconnect the exhaust pipe support, and remove the exhaust pipe assembly front and 2 gaskets.

  5. REMOVE PROPELLER SHAFT ASSEMBLY (for Long Wheelbase)


    1. B007W0TE01

      Put matchmarks on both flanges.

    2. Remove the 4 nuts, bolts and washers.

      Tech Tips

      If the flange connection is hard to separate, temporarily tighten one nut only and evenly tap the flange with a brass bar and hammer to separate the propeller shaft assembly from the differential companion flange.

    3. Remove the propeller shaft assembly.

    4. B007UO6E01

      Insert SST in the transmission to prevent oil leakage.

      Note

      Do not damage the oil seal.


      1. Use the following SST for the automatic transmission

        SST
        09325-40010

      2. Use the following SST for the manual transmission

        SST
        09325-20010

  6. REMOVE PROPELLER WITH CENTER BEARING SHAFT ASSEMBLY (for Super Long Wheelbase)


    1. B007W0TE01

      Put matchmarks on both flanges.

    2. Remove the 4 nuts, bolts and washers.

      Tech Tips

      If the flange connection is hard to separate, temporarily tighten one nut only and evenly tap the flange with a brass bar and hammer to separate the propeller with center bearing shaft assembly from the differential companion flange.

    3. B007PGH

      Remove the 2 bolts and center support bearing assembly No.1.

    4. Remove the propeller with center bearing shaft assembly.

    5. B007UO6E01

      Insert SST in the transmission to prevent oil leakage.

      Note

      Do not damage the oil seal.


      1. Use the following SST for the automatic transmission.

        SST
        09325-40010

      2. Use the following SST for the manual transmission.

        SST
        09325-20010

  7. SEPARATE TRANSMISSION CONTROL CABLE ASSEMBLY


    1. B007VCTE01

      Put matchmarks on the control cable assembly and the outer lever.

    2. Remove the 2 nuts and separate the transmission control cable from the outer lever.

    3. B007UDO

      Using a screwdriver, disengage the claws of the 2 clips.

    4. Remove the transmission control cable and 2 clips from the transmission control cable bracket No.1.

  8. DISCONNECT WIRE HARNESS


    1. B007ONV

      Disconnect the 2 connectors and clamps.

    2. B007T6K

      Separate the wire harness clamp from the manual transmission.

    3. Remove the 2 bolts and separate the ground cable.

  9. SEPARATE CLUTCH RELEASE CYLINDER ASSEMBLY


    1. B007SW0

      Remove the 2 bolts and separate the clutch release cylinder

  10. REMOVE STARTER ASSEMBLY (for 2.0kW Type)


    1. B007V15E01

      for Wide Body:

      Remove the bolt, then remove the ground cable.

    2. B007QWSE01

      Open the terminal cap.

    3. Remove the nut and disconnect the wire harness from terminal 30.

    4. Disconnect the terminal 50 connector from the starter assembly.

    5. B007S64E01

      Remove the bolt and 2 nuts, then remove the starter.

  11. REMOVE STARTER ASSEMBLY (for 2.2 kW Type)


    1. B007TYT

      Remove the No. 2 terminal cap.

    2. Disconnect the starter connector.

    3. Remove the nut and disconnect the starter wire.

    4. B007TYZ

      Remove the 2 bolts and disconnect the wiring harness clamp bracket.

    5. Remove the stater assembly.

  12. REMOVE STARTER ASSEMBLY (for 2.7 kW Type)


    1. B007V15E01

      for Wide Body:

      Remove the bolt, then disconnect the ground cable.

    2. B007QWSE01

      Open the terminal cap.

    3. Remove the nut and disconnect the wire harness from terminal 30.

    4. Disconnect the terminal 50 connector from the starter assembly.

    5. B007S64E01

      Remove the bolt and 2 nuts, then remove the starter.

  13. REMOVE MANUAL TRANSMISSION UNIT ASSEMBLY


    1. B007R0C

      Support the manual transmission unit with a transmission jack.

    2. Remove the bolt, nut, and 2 washers, and then separate the transmission unit from the frame.

    3. B007PA8E01

      Remove the 9 bolts, manual transmission unit, control cable bracket No.1, rear end plate, and cylinder block insulator.

      Tech Tips


      • The A bolts in the illustration tighten the control cable bracket together.


      • The B bolts in the illustration tighten the rear end plate together.


      • Bolt C in the illustration tightens the harness clamp bracket together.

  14. REMOVE EXTENSION HOUSING DYNAMIC(MTM) DAMPER (WITH DYNAMIC DAMPER)


    1. B007Q1Y

      Remove the 4 bolts and extension housing dynamic (MTM) damper.

  15. REMOVE REAR ENGINE MOUNTING INSULATOR ASSEMBLY


    1. B007V53

      Remove the 4 bolts and rear engine mounting insulator assembly.