MANUAL TRANSMISSION ASSEMBLY (for 1KD-FTV) 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 DIFFERENTIAL PRESSURE SENSOR ASSEMBLY (w/ DPF)


    1. Install the differential pressure sensor assembly to the sensor bracket with the nut.

      Torque:
      5.0 N*m  { 51 kgf*cm, 44 in.*lbf }

  3. 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 }

  4. INSTALL MANUAL TRANSMISSION WITH TRANSFER


    1. Install the manual transmission with transfer with the 8 bolts.

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

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


    1. w/o DPF:


      1. Connect the 3 breather hoses.

      2. Attach the breather hose clamp.

    2. w/ DPF:


      1. Connect the 3 breather hoses.

      2. Attach the 2 breather hose clamps.

  6. CONNECT WIRE HARNESS


    1. w/o DPF:


      1. Attach the 5 wire harness clamps.

      2. Connect the 2 connector.

    2. w/ DPF:


      1. Attach the 8 wire harness clamps.

      2. Connect the 3 connectors and 3 connector clamps.

  7. 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 }

  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. CONNECT CLUTCH RELEASE CYLINDER ASSEMBLY


    1. Connect the release cylinder with the 2 bolts.

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

    2. Install a new clip to the flexible hose.

  12. INSTALL STARTER ASSEMBLY

    for 2.2 kW Type: Click here

    for 2.7 kW Type: Click here

  13. INSTALL PROPELLER SHAFT ASSEMBLY

    Click here

  14. INSTALL FRONT PROPELLER SHAFT ASSEMBLY

    Click here

  15. 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 }

  16. INSTALL FRONT EXHAUST PIPE ASSEMBLY

    w/o DPF: Click here

    w/ DPF: Click here

  17. ADD MANUAL TRANSMISSION OIL

  18. 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 }

  19. 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. A01DNQUE02
      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.

  20. INSTALL NO. 1 SHIFT AND SELECT LEVER BOOT


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

  21. 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.

  22. INSTALL SHIFT LEVER KNOB SUB-ASSEMBLY

  23. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

    Note

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