MANUAL TRANSMISSION ASSEMBLY (for 1GR-FE) 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 TRANSMISSION UPPER COVER SUB-ASSEMBLY


    1. Install the upper cover with the 2 bolts.

      Torque:
      12 N*m  { 117 kgf*cm, 8 ft.*lbf }
  3. INSTALL MANUAL TRANSMISSION WITH TRANSFER

    A01DT49E02

    1. Install the manual transmission with transfer with the 9 bolts.

      Torque:
      for bolt A
      72 N*m  { 729 kgf*cm, 53 ft.*lbf }
      for bolt B
      37 N*m  { 379 kgf*cm, 27 ft.*lbf }
  4. CONNECT TRANSFER AND MANUAL TRANSMISSION BREATHER HOSE SUB-ASSEMBLY


    1. Connect the 2 breather hoses to the transfer adapter.

    2. Connect the 4 breather hoses to the bracket and clutch housing.

    3. Attach the breather hose clamp.

  5. CONNECT WIRE HARNESS


    1. Connect the wire harness with the bolt.

      Torque:
      8.0 N*m  { 82 kgf*cm, 71 in.*lbf }
    2. Attach the 7 clamps.

    3. Connect the 2 connectors.

  6. INSTALL REAR NO. 1 ENGINE MOUNTING INSULATOR


    1. Install the engine No. 1 mounting insulator rear with the 4 bolts.

      Torque:
      65 N*m  { 663 kgf*cm, 48 ft.*lbf }
  7. INSTALL FRONT ENGINE MOUNTING INSULATOR RH


    1. Install the insulator with the bolt.

      Torque:
      12 N*m  { 117 kgf*cm, 8 ft.*lbf }
  8. INSTALL NO. 3 FRAME CROSSMEMBER SUB-ASSEMBLY


    1. Install the No. 3 frame crossmember sub-assembly with the 4 bolts and 4 nuts.

      Torque:
      72 N*m  { 734 kgf*cm, 53 ft.*lbf }
    2. Install the 4 bolts to the No. 3 frame crossmember sub-assembly.

      Torque:
      30 N*m  { 306 kgf*cm, 22 ft.*lbf }
  9. INSTALL FRONT SUSPENSION MEMBER BRACKET LH


    1. Install the front suspension member bracket LH with the 4 bolts.

      Torque:
      33 N*m  { 337 kgf*cm, 24 ft.*lbf }
  10. INSTALL FRONT SUSPENSION MEMBER BRACKET RH


    1. Install the front suspension member bracket RH with the 4 bolts.

      Torque:
      33 N*m  { 337 kgf*cm, 24 ft.*lbf }
  11. INSTALL CLUTCH ACCUMULATOR ASSEMBLY


    1. Install the clutch accumulator Click here.

  12. INSTALL CLUTCH RELEASE CYLINDER ASSEMBLY


    1. Install the release cylinder Click here.

  13. INSTALL STARTER ASSEMBLY


    1. Install the starter Click here.

  14. INSTALL PROPELLER SHAFT ASSEMBLY


    1. Install the propeller shaft Click here.

  15. INSTALL FRONT PROPELLER SHAFT ASSEMBLY


    1. Install the front propeller shaft Click here.

  16. INSTALL TRANSFER CASE LOWER PROTECTOR


    1. Install the transfer case lower protector with the 4 bolts.

      Torque:
      18 N*m  { 184 kgf*cm, 13 ft.*lbf }
  17. INSTALL PROPELLER SHAFT HEAT INSULATOR


    1. Install the propeller shaft heat insulator with the 2 bolts.

      Torque:
      16 N*m  { 160 kgf*cm, 12 ft.*lbf }
  18. INSTALL MANIFOLD STAY


    1. Install the manifold stay with the 3 bolts.

      Torque:
      40 N*m  { 408 kgf*cm, 30 ft.*lbf }
  19. INSTALL NO. 2 MANIFOLD STAY


    1. Install the manifold stay with the 3 bolts.

      Torque:
      40 N*m  { 408 kgf*cm, 30 ft.*lbf }
  20. INSTALL FRONT EXHAUST PIPE ASSEMBLY


    1. Install the front exhaust pipe Click here.

  21. ADD MANUAL TRANSMISSION OIL

  22. INSPECT MANUAL TRANSMISSION OIL


    1. Park the vehicle on a level surface.

    2. A01DNZPE07

      Check that the oil level is between 0 to 5 mm (0 to 0.196 in.) from the bottom lip of the filler plug opening.


      • If the result is not as specified, add transmission oil.

      Note


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

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

    3. Inspect for oil leaks when the oil level is low.


      • If the result is not as specified, add transmission oil.

    4. Install a new gasket and the filler plug.

      Torque:
      37 N*m  { 377 kgf*cm, 27 ft.*lbf }
  23. INSTALL FLOOR SHIFT SHIFT LEVER ASSEMBLY

    A01DNXZE03

    1. Apply MP grease to the tip of the shift lever.

      Text in Illustration
      A01DQPB MP Grease
    2. A01DPR1E01
      Text in Illustration
      *1 Cloth
      *a Down
      *b Clockwise

      Cover the shift lever cap with a cloth.

    3. While pressing down on the shift lever cap, turn it clockwise to install the shift lever.

  24. INSTALL NO. 1 SHIFT AND SELECT LEVER BOOT


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

    2. Attach the 2 clips.

  25. 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.

  26. INSTALL SHIFT LEVER KNOB SUB-ASSEMBLY


    1. Install the knob to the shift lever.

  27. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

    Note

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