MANUAL TRANSMISSION ASSEMBLY INSTALLATION


  1. INSTALL TRANSFER ASSEMBLY


    1. for 1KD-FTV:

      Install the transfer assembly with the 8 bolts and 2 brackets.

      Torque:
      24 N*m  { 245 kgf*cm, 18 ft.*lbf }

      Note

      Take care not to damage the adaptor rear oil seal with the transfer input gear spline.

    2. except 1KD-FTV:

      Install the transfer assembly with the 8 bolts and bracket.

      Torque:
      24 N*m  { 245 kgf*cm, 18 ft.*lbf }

      Note

      Take care not to damage the adaptor rear oil seal with the transfer input gear spline.

  2. INSTALL MANUAL TRANSMISSION UNIT ASSEMBLY


    1. A01DSRG

      Confirm that 2 straight pins are on the manual transmission contact surface of the engine cylinder block before manual transmission installation.

    2. Align the input shaft with the clutch disc and install the transmission unit to the engine.

    3. A01DUM1E01

      Install the 8 bolts.

      Torque:
      for bolt A
      72 N*m  { 729 kgf*cm, 52 ft.*lbf }
      for bolt B
      37 N*m  { 379 kgf*cm, 27 ft.*lbf }

  3. CONNECT TRANSFER AND MANUAL TRANSMISSION BREATHER HOSE SUB-ASSEMBLY


    1. Connect the 2 breather hoses to the bracket.

    2. Connect the 3 breather hoses to the transfer adapter and transfer.

  4. CONNECT WIRE HARNESS


    1. Connect the 2 connectors and 4 clamps.

  5. INSTALL MANIFOLD STAY


    1. A01DM05E01

      Install the manifold stay with the 3 bolts.

      Torque:
      for bolt A
      71 N*m  { 724 kgf*cm, 52 ft.*lbf }
      for bolt B
      44 N*m  { 449 kgf*cm, 32 ft.*lbf }
      for bolt C
      30 N*m  { 360 kgf*cm, 22 ft.*lbf }

  6. INSTALL REAR NO. 1 ENGINE MOUNTING INSULATOR


    1. A01DSNSE01

      Install the mounting insulator and front engine mounting insulator with the 5 bolts.

      Torque:
      for bolt A
      65 N*m  { 663 kgf*cm, 48 ft.*lbf }
      for bolt B
      12 N*m  { 117 kgf*cm, 8 ft.*lbf }

  7. INSTALL NO. 3 FRAME CROSSMEMBER SUB-ASSEMBLY


    1. Install the frame crossmember with the 4 bolts and 4 nuts.

      Torque:
      72 N*m  { 734 kgf*cm, 53 ft.*lbf }

    2. Install the 4 bolts to the mounting insulator.

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

  8. INSTALL FRONT SUSPENSION MEMBER BRACKET LH


    1. Install the member bracket with the 4 bolts.

      Torque:
      33 N*m  { 337 kgf*cm, 24 ft.*lbf }

  9. INSTALL FRONT SUSPENSION MEMBER BRACKET RH


    1. Install the member bracket with the 4 bolts.

      Torque:
      33 N*m  { 337 kgf*cm, 24 ft.*lbf }

  10. INSTALL STARTER ASSEMBLY


    1. for 1.4 kW Type:

      Install the starter Click here.

    2. for 2.0 kW Type:

      Install the starter Click here.

  11. CONNECT CLUTCH RELEASE CYLINDER ASSEMBLY


    1. Connect the clutch release cylinder with the 2 bolts.

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

  12. INSTALL FRONT PROPELLER SHAFT ASSEMBLY


    1. Install the front propeller shaft Click here.

  13. INSTALL PROPELLER SHAFT ASSEMBLY


    1. Install the propeller shaft Click here.

  14. ADD MANUAL TRANSMISSION OIL

  15. INSTALL TRANSFER CASE LOWER PROTECTOR


    1. Install the lower protector with the 4 bolts.

      Torque:
      18 N*m  { 184 kgf*cm, 13 ft.*lbf }

  16. INSTALL FLOOR SHIFT SHIFT LEVER ASSEMBLY


    1. Cover the shift lever cap with a cloth.

    2. Press down on the shift lever cap and rotate it clockwise to install it.

      Tech Tips

      Apply MP grease to the tip of the shift lever.

  17. INSTALL NO. 1 SHIFT AND SELECT LEVER BOOT


    1. Install the shift and select lever boot with the 4 screws.

    2. Attach the 2 clips.

  18. INSTALL CONSOLE PANEL SUB-ASSEMBLY


    1. Install the rear console box Click here.

    2. w/ Refrigerated Cool Box:

      Install the rear console box Click here.

  19. INSTALL SHIFT LEVER KNOB SUB-ASSEMBLY


    1. Install the knob to the shift lever.

  20. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

    Note

    When disconnecting the cable, some systems need to be initialized after the cable is reconnected Click here.