MANUAL TRANSMISSION ASSEMBLY (for 1KD-FTV) INSTALLATION


  1. INSTALL REAR ENGINE MOUNTING INSULATOR ASSEMBLY


    1. B007V53

      Install the rear engine mounting insulator assembly with the 4 bolts.

      Torque:
      29 N*m  { 296 kgf*cm, 21 ft.*lbf }

  2. INSTALL EXTENSION HOUSING DYNAMIC DAMPER (WITH DYNAMIC DAMPER)

    B007Q1Y

    1. Install the extension housing dynamic damper with the 4 bolts.

      Torque:
      30 N*m  { 306 kgf*cm, 22 ft.*lbf }

  3. INSTALL MANUAL TRANSMISSION ASSEMBLY


    1. B007PA8E01

      Install the manual transmission assembly with the 9 bolts.

      Torque:
      72 N*m  { 729 kgf*cm, 53 ft.*lbf }

      Tech Tips


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


      • The B bolts in the illustration tighten the stiffener plate together.


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

    2. B007R0C

      Install the transmission assembly to the frame with the bolt, nut, and 2 washers.

      Torque:
      98 N*m  { 999 kgf*cm, 72 ft.*lbf }

      Note


      • Insert the bolt from the left side of the vehicle.

      • Tighten the nut while holding the bolt.

  4. INSTALL STARTER ASSEMBLY (for 2.2 kW Type)


    1. for Automatic Transmission:


      1. Install the starter with the bolt and 2 nuts.

        Torque:
        68 N*m  { 693 kgf*cm, 50 ft.*lbf }

    2. for Manual Transmission:


      1. Install the starter with the bolt and nut.

        Torque:
        68 N*m  { 693 kgf*cm, 50 ft.*lbf }

    3. Connect the wire harness to terminal 30 with the nut.

      Torque:
      9.8 N*m  { 100 kgf*cm, 87 in.*lbf }

    4. Close the terminal cap.

    5. Connect the terminal 50 connector to the starter.

    6. for Wide Body:

      Install the ground cable with the bolt.

      Torque:
      25 N*m  { 250 kgf*cm, 18 ft.*lbf }

  5. INSTALL STARTER ASSEMBLY (for 2.7 kW Type)


    1. B007V7W

      for Automatic Transmission:

      Install the starter with the bolt and 2 nuts.

      Torque:
      68 N*m  { 693 kgf*cm, 50 ft.*lbf }
    2. B007VMZ

      for Manual Transmission:

      Install the starter with the bolt and nut.

      Torque:
      68 N*m  { 693 kgf*cm, 50 ft.*lbf }
    3. B007QWSE01

      Connect the wire harness to terminal 30 with the nut.

      Torque:
      21 N*m  { 214 kgf*cm, 15 ft.*lbf }

    4. Close the terminal cap.

    5. Connect the terminal 50 connector to the starter.

    6. B007V15E01

      for Wide Body:

      Install the wire ground cable with the bolt.

      Torque:
      25 N*m  { 250 kgf*cm, 18 ft.*lbf }

  6. INSTALL CLUTCH RELEASE CYLINDER ASSEMBLY


    1. B007SW0

      Install the clutch release cylinder assembly with the 2 bolts.

      Torque:
      12 N*m  { 119 kgf*cm, 8.6 ft.*lbf }

  7. INSTALL WIRE HARNESS


    1. Connect the speed sensor connector.

    2. Connect the back-up light switch connector.

    3. Install the ground cable with the bolt.

      Torque:
      13 N*m  { 130 kgf*cm, 10 ft.*lbf }

  8. CONNECT TRANSMISSION CONTROL CABLE ASSEMBLY


    1. B007T5UE01

      Install 2 new clips to the No. 1 transmission control cable bracket.

    2. Connect the transmission control cable assembly to the No. 1 transmission control cable bracket.

      Note


      • Make sure that A claws of the clips are firmly installed into the bracket grooves.

      • Make sure that the cable is set in the clip with both B claws erected to prevent slippage of the cable in the opposite direction.

    3. B007VCTE02

      Align the matchmarks on the control cable assembly and the shift outer lever.

    4. Align the matchmarks on the control cable assembly and the select outer lever.

    5. Install the transmission control cable assembly to the shift outer lever with the nut.

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

    6. Install the transmission control cable assembly to the select outer lever with the nut.

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

  9. INSTALL TRANSMISSION CONTROL CABLE INSULATOR (for RHD)


    1. B007OMA

      Install the No. 1 transmission control cable insulator to the select outer lever with the nut.

      Torque:
      10 N*m  { 102 kgf*cm, 7 ft.*lbf }

    2. Install the No. 2 transmission control cable insulator to the No. 1 transmission control cable bracket with the 2 nut.

      Torque:
      10 N*m  { 102 kgf*cm, 7 ft.*lbf }

  10. INSTALL PROPELLER SHAFT ASSEMBLY (for Long Wheelbase)

    Click here

  11. INSTALL PROPELLER WITH CENTER BEARING SHAFT ASSEMBLY (for Super Long Wheelbase)

    Click here

  12. INSTALL EXHAUST MANIFOLD CONVERTER SUB-ASSEMBLY (w/o DPF)


    1. Install a new gasket and the exhaust manifold converter sub-assembly with 3 new nuts.

      Torque:
      30 N*m  { 306 kgf*cm, 22 ft.*lbf }

  13. TEMPORARILY INSTALL TURBINE OUTLET ELBOW STAY


    1. w/ DPF:


      1. Temporarily install the turbine outlet elbow stay with the 2 bolts.

    2. w/o DPF:


      1. Temporarily install the turbine outlet elbow stay with the 2 bolts and 2 new nuts.

      2. Tighten the 2 bolts.

        Torque:
        62 N*m  { 632 kgf*cm, 46 ft.*lbf }

  14. INSTALL CATALYTIC WITH PIPE CONVERTER ASSEMBLY (w/ DPF)


    1. B007OMU

      Install a new gasket and the catalytic with pipe converter assembly with 3 new nuts.

      Torque:
      30 N*m  { 306 kgf*cm, 22 ft.*lbf }

    2. Temporarily install 2 new nuts.

    3. Tighten the 2 bolts of the turbine outlet elbow stay.

      Torque:
      62 N*m  { 632 kgf*cm, 46 ft.*lbf }

  15. INSTALL NO. 3 EXHAUST MANIFOLD HEAT INSULATOR (w/ DPF)


    1. Install the No. 3 exhaust manifold heat insulator with the 2 bolts.

      Torque:
      13 N*m  { 133 kgf*cm, 10 ft.*lbf }

  16. INSTALL NO. 2 EXHAUST MANIFOLD HEAT INSULATOR (w/ DPF)


    1. Install the No. 2 exhaust manifold heat insulator with the 2 bolts.

      Torque:
      13 N*m  { 133 kgf*cm, 10 ft.*lbf }

  17. INSTALL FRONT EXHAUST PIPE ASSEMBLY (w/ DPF)

    Click here

  18. INSTALL FRONT EXHAUST PIPE ASSEMBLY (w/o DPF)


    1. B007V6Q

      Inspect the compression spring.


      1. Using a vernier caliper measure the free length of the compression spring.

        Minimum length
        40.5 mm (1.59 in.)

        If the free length is less than the minimum, replace the compression spring.

    2. B007TGQE02
      Text in Illustration
      *1 Gasket
      *a Wooden Block

      Fully push a new gasket onto the exhaust manifold converter sub-assembly by hand.

    3. Using a wooden block, uniformly strike the gasket so that the gasket and exhaust manifold converter sub-assembly fit together properly.

      Note


      • Install the gasket in the correct direction.

      • Do not damage the outer surface of the gasket.

      • Do not reuse the removed gasket.

      • Do not push in the gasket with the front exhaust pipe assembly when connecting the pipe.

    4. Connect the front exhaust pipe assembly to the No. 4 exhaust pipe support.

    5. Install the front exhaust pipe assembly and 2 compression springs with the 2 bolts and 2 nuts.

      Torque:
      for bolt
      43 N*m  { 438 kgf*cm, 32 ft.*lbf }
      for nut
      48 N*m  { 489 kgf*cm, 35 ft.*lbf }

  19. ADD MANUAL TRANSMISSION OIL


    1. B007P4BE01

      Park the vehicle in a level place.

    2. Remove the transmission filler plug and gasket.

    3. Check that the oil surface is within 5 mm (0.20 in.) below the lowest point of the transmission filler plug opening.

      Oil grade
      TOYOTA Genuine Manual Transmission Gear oil API GL-3 (GL-4) or equivalent
      Viscosity
      Above -10°C (14°F): SAE 75W-90, 80W or 80W-90
      Below -10°C (14°F): SAE 75W-90
      Capacity
      2.6 liters (2.7 US qts, 2.3 Imp. qts)

      Note


      • Problems may occur when the oil level is too high or too low.

      • After replacing the oil, drive the vehicle and check the oil level again.

    4. Check for oil leakage if the oil level is low.

    5. Install the transmission filler plug and a new gasket.

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

  20. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

    Torque:
    5.4 N*m  { 55 kgf*cm, 47 in.*lbf }

  21. INSPECT FOR EXHAUST GAS LEAK

  22. INSPECT FOR OIL LEAK

  23. PERFORM INITIALIZATION

    Some systems need initialization after reconnecting the cable to the negative battery terminal. Click here