MANUAL TRANSMISSION ASSEMBLY INSTALLATION

PROCEDURE


  1. INSTALL CLUTCH RELEASE FORK SUB-ASSEMBLY

    Click here

  2. INSTALL TRANSFER ASSEMBLY

    Click here

  3. INSTALL MANUAL TRANSMISSION WITH TRANSFER (for 1GR-FE)

    B001VW8E02

    Note

    Check that the 2 straight pins are attached to the engine side.


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

      Torque:
      for bolt A
      72 N*m  { 730 kgf*cm, 53 ft.*lbf }
      for bolt B
      37 N*m  { 380 kgf*cm, 28 ft.*lbf }
      Bolt Length
      Item Length
      Bolt A 50 mm (1.97 in.)
      Bolt B 45 mm (1.77 in.)

  4. INSTALL MANUAL TRANSMISSION WITH TRANSFER (for 1VD-FTV)

    B001ZWAE02

    Note

    Check that the 2 straight pins are attached to the engine side.


    1. Install the manual transmission with transfer with the 10 bolts.

      Torque:
      for bolt A and B
      72 N*m  { 730 kgf*cm, 53 ft.*lbf }
      for bolt C
      39 N*m  { 400 kgf*cm, 29 ft.*lbf }
      Bolt Length
      Item Length
      Bolt A 45 mm (1.77 in.)
      Bolt B 50 mm (1.97 in.)
      Bolt C 70 mm (2.76 in.)

  5. INSTALL OIL PAN COVER (for 1VD-FTV)

    B002027

    1. Install the oil pan cover with the 2 bolts.

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

  6. INSTALL CLUTCH RELEASE CYLINDER TO FLEXIBLE HOSE TUBE

    B001XE1E02
    *1 for 1GR-FE:
    *2 for 1VD-FTV:

    1. Install the flexible hose tube with the 3 bolts.

      Torque:
      20 N*m  { 204 kgf*cm, 15 ft.*lbf }

  7. INSTALL CLUTCH RELEASE CYLINDER ASSEMBLY

    B001WWY

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

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

  8. INSTALL CLUTCH ACCUMULATOR ASSEMBLY

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  9. INSTALL CLUTCH RELEASE CYLINDER TO ACCUMULATOR TUBE

    Click here

  10. INSTALL NO. 1 CLUTCH HOUSING COVER

    B001ZYP

    1. Install the housing cover with the 3 bolts.

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

  11. CONNECT WIRE HARNESS (for 1GR-FE)

    B001ZOBE02
    *1 LH Side:
    *2 RH Side:

    1. Connect the 6 clamps.

    2. Connect the back-up light switch connector.

    3. Install the 2 bolts.

      Torque:
      for LH side
      29 N*m  { 296 kgf*cm, 21 ft.*lbf }
      for RH side
      60 N*m  { 612 kgf*cm, 44 ft.*lbf }
    4. B001WDU

      Connect the ground cable with the bolt.

      Torque:
      8.0 N*m  { 82 kgf*cm, 71 in.*lbf }
    5. B001XRU

      Connect the 2 connectors and 3 clamps.

  12. CONNECT WIRE HARNESS (for 1VD-FTV)

    B001Z9W

    1. Connect the 5 clamps.

    2. Connect the back-up light switch connector.

    3. Connect the shift position switch connector.

    4. B001WDU

      Connect the ground cable with the bolt.

      Torque:
      8.0 N*m  { 82 kgf*cm, 71 in.*lbf }
    5. B001XRU

      Connect the 2 connectors and 3 clamps.

  13. INSTALL TRANSFER BREATHER HOSE SUB-ASSEMBLY (for 1GR-FE)

    B001Y69

    1. Connect the 2 breather hoses to the bracket.

    2. B001ZIG

      Connect the 5 clamps.

    3. B001YCO

      Connect the breather hose to the transfer and actuator, and attach the 2 clamps.

  14. INSTALL TRANSFER BREATHER HOSE SUB-ASSEMBLY (for 1VD-FTV)

    B001VSA

    1. Install the bracket with the bolt.

    2. Connect the 3 breather hoses to the bracket.

    3. B001Z5P

      Connect the 3 clamps.

    4. B001YCO

      Connect the breather hose to the transfer and actuator, and attach the 2 clamps.

  15. INSTALL REAR NO. 1 ENGINE MOUNTING INSULATOR

    B001X9M

    1. Install the engine mounting insulator to the transmission with the 4 bolts.

      Torque:
      59 N*m  { 602 kgf*cm, 44 ft.*lbf }

  16. INSTALL NO. 2 FRAME CROSSMEMBER SUB-ASSEMBLY

    B001ZEO

    1. Install the frame crossmember to the rear engine mounting insulator with the 4 bolts.

      Torque:
      37 N*m  { 377 kgf*cm, 27 ft.*lbf }
    2. B001YAQ

      Install the frame crossmember to the vehicle body with the 4 bolts, 4 washers and 4 nuts.

      T = 110 N*m{ 1,122 kgf*cm 81 ft.*lbf }

  17. INSTALL STARTER ASSEMBLY (for 1GR-FE)

    Click here

  18. INSTALL NO. 2 MANIFOLD STAY (for 1GR-FE)

    Click here

  19. INSTALL MANIFOLD STAY (for 1GR-FE)

    Click here

  20. INSTALL EXHAUST PIPE (for 1GR-FE)

    Click here

  21. INSTALL EXHAUST PIPE (for 1VD-FTV)

    w/o DPF: Click here

    w/ DPF: Click here

  22. INSTALL FRONT PROPELLER SHAFT ASSEMBLY

    Click here

  23. INSTALL PROPELLER SHAFT ASSEMBLY

    Click here

  24. ADD MANUAL TRANSMISSION OIL

  25. INSPECT TRANSMISSION OIL

    Click here

  26. INSTALL LOWER TRANSFER CASE PROTECTOR

    B001WZ4

    1. Install the lower transfer case protector with the 7 bolts.

      Torque:
      14 N*m  { 139 kgf*cm, 10 ft.*lbf }

  27. INSTALL TRANSFER DYNAMIC DAMPER (for 1VD-FTV)

    B001YCJ

    1. Install the transfer dynamic damper with the 2 bolts.

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

  28. INSTALL TRANSFER HEAT INSULATOR

    Click here

  29. INSTALL TUBE CONNECTOR TO FLEXIBLE HOSE TUBE (for 1VD-FTV)

    Click here

  30. INSTALL AIR TUBE SUB-ASSEMBLY LH (for 1VD-FTV)

    Click here

  31. INSTALL CLUTCH HOSE (for 1VD-FTV)

    Click here

  32. INSTALL NO. 2 COOL AIR INLET (w/o Intercooler)

    Click here

  33. INSTALL INTERCOOLER ASSEMBLY (w/ Intercooler)

    Click here

  34. INSTALL NO. 1 ENGINE COVER SUB-ASSEMBLY

    Click here

  35. INSTALL FLOOR SHIFT LEVER ASSEMBLY


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

    2. Cover the shift lever cap with a cloth.

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

  36. INSTALL SHIFT LEVER BOOT ASSEMBLY

    B001W19

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

  37. INSTALL UPPER CONSOLE PANEL SUB-ASSEMBLY

    w/o Console Box Lid Click here

    w/ Cool Box Click here

    w/o Cool Box Click here

  38. FILL RESERVOIR WITH BRAKE FLUID

    Click here

  39. BLEED CLUTCH LINE

    Click here

  40. CHECK FLUID LEVEL IN RESERVOIR

    Click here

  41. INSPECT FOR CLUTCH FLUID LEAK

  42. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

    Note

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