MANUAL TRANSMISSION ASSEMBLY (for 1KD-FTV) INSTALLATION


  1. INSTALL REAR ENGINE MOUNTING INSULATOR ASSEMBLY


    1. A01KIHA

      Install the rear engine mounting insulator with the 4 bolts.

      Torque:
      45 N*m  { 459 kgf*cm, 33 ft.*lbf }
    2. A01KG8H

      Connect the shift cable link with the nut.

      Torque:
      12 N*m  { 122 kgf*cm, 9 ft.*lbf }

  2. INSTALL MANUAL TRANSMISSION ASSEMBLY


    1. A01KFR5

      Install the manual transmission with the 5 bolts.

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

  3. INSTALL NO. 2 REAR END PLATE


    1. A01KGS0

      Install the No. 2 rear end plate with the 4 bolts.

      Torque:
      73 N*m  { 744 kgf*cm, 54 ft.*lbf }

  4. INSTALL NO. 4 CYLINDER BLOCK INSULATOR


    1. A01KFE3

      Install the No. 4 cylinder block insulator.

  5. INSTALL REAR ENGINE MOUNTING INSULATOR ASSEMBLY


    1. A01KHS7

      Install the rear engine mounting insulator onto the rear engine mounting bracket with the bolt and nut.

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

  6. INSTALL CLUTCH RELEASE CYLINDER ASSEMBLY


    1. A01KGF9

      Install the clutch release cylinder with the 2 bolts.

      Torque:
      12 N*m  { 120 kgf*cm, 9 ft.*lbf }

  7. INSTALL STARTER ASSEMBLY


    1. Install the starter with the bolt and nut.

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

    2. Install the wire harness with the nut.

      Torque:
      9.8 N*m  { 100 kgf*cm, 7 ft.*lbf }

    3. Connect the connector.

  8. CONNECT TRANSMISSION CONTROL SELECT CABLE


    1. A01KH0E

      Connect the select cable with a new clip and nut.

      Torque:
      12 N*m  { 122 kgf*cm, 9 ft.*lbf }

  9. CONNECT TRANSMISSION CONTROL SHIFT CABLE


    1. A01KGOB

      Connect the shift cable with a new clip and nut.

      Torque:
      12 N*m  { 122 kgf*cm, 9 ft.*lbf }

  10. CONNECT WIRE HARNESS


    1. Connect the speed sensor connector.

    2. Connect the back-up light connector.

  11. INSTALL PARKING BRAKE PLATE SUB-ASSEMBLY


    1. Install the parking brake plate sub-assembly with the 4 bolts.

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

  12. INSTALL PARKING BRAKE DRUM SUB-ASSEMBLY


    1. Install the brake drum, new O-ring and new nut.

    2. Using a socket wrench (32mm), tight the nut.

      Torque:
      127 N*m  { 1300 kgf*cm, 94 ft.*lbf }

  13. INSTALL REAR PROPELLER SHAFT ASSEMBLY (for 2 Joint Type)

    A01KEMLE02
    Text in Illustration
    *a Matchmark

    1. Align the matchmarks on the propeller shaft flange and parking brake drum.

    2. Install the 4 nuts and 4 washers.

      Torque:
      M10 Nut
      74 N*m  { 749 kgf*cm, 54 ft.*lbf }
      M11 Nut
      88 N*m  { 899 kgf*cm, 65 ft.*lbf }
    3. A01KI9TE02
      Text in Illustration
      *a Matchmark

      Align the matchmarks on the propeller shaft flange and differential flange.

    4. Install the 4 nuts, 4 bolts and 4 washers.

      Torque:
      M10 Nut
      74 N*m  { 749 kgf*cm, 54 ft.*lbf }
      M11 Nut
      88 N*m  { 899 kgf*cm, 65 ft.*lbf }

  14. INSTALL REAR PROPELLER SHAFT ASSEMBLY (for 3 Joint Type)

    Click here

  15. INSTALL FRONT EXHAUST PIPE ASSEMBLY


    1. A01KEXT

      Inspect the compression spring.


      1. Using vernier calipers, measure the free length of the compression spring.

        Minimum length
        40.5 mm (1.594 in.)

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

    2. A01KH27E02
      Text in Illustration
      *1 New Gasket
      *a Wooden Block

      Fully insert a new gasket into the turbine outlet elbow by hand.

      Note


      • Install the gasket in the correct direction.

      • Do not damage the outer surface of the gasket.

      • Do not reuse the gasket.

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

    3. Using a wooden block, uniformly strike the gasket so that the gasket and the turbine outlet elbow are properly fitted.

    4. A01KIEL

      Install the 2 hungers and the front exhaust pipe.

    5. Install the 2 bolts and the 2 compression springs.

      Torque:
      43 N*m  { 438 kgf*cm, 32 ft.*lbf }

  16. ADD MANUAL TRANSMISSION OIL

  17. INSPECT AND ADJUST MANUAL TRANSMISSION OIL


    1. Stop the vehicle on the level place.

    2. Remove the transmission filler plug and gasket.

    3. A01KF8SE53
      Text in Illustration
      *a 0 to 5 mm (0 to 0.20 in.)

      Check that the oil surface is within 5 mm (0.20 in.) from the lowest position of the inner surface of the transmission filler plug opening.

      Note


      • Excessively large or small amount of oil may cause troubles.

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

    4. Check for oil leakage when 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 }

  18. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

    Torque:
    3.9 N*m  { 39 kgf*cm, 34 in.*lbf }

  19. INSPECT FOR OIL LEAK

  20. INSPECT FOR EXHAUST GAS LEAK