MANUAL TRANSMISSION ASSEMBLY(for 1KD-FTV) REMOVAL

PROCEDURE


  1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL

    Note


    • After turning the ignition switch off, waiting time may be required before disconnecting the cable from the battery terminal. Therefore, make sure to read the disconnecting the cable from the battery terminal notice before proceeding with work Click here.

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

  2. REMOVE CONSOLE BOX ASSEMBLY

    for Manual Transmission: Click here

    w/ Refrigerated Cool Box: Click here

  3. REMOVE NO. 1 SHIFT AND SELECT LEVER BOOT

    B001EZL

    1. Remove the 4 screws and No. 1 shift and select lever boot.

  4. REMOVE SHIFT LEVER ASSEMBLY

    B001F0E

    1. Detach the shift lever cap boot from the manual transmission.

    2. Cover the shift lever cap with a cloth.

    3. B001CM1E01
      Text in Illustration
      *1 Shift Lever Cap
      *a Press Down
      *b Counterclockwise
      *c Pull out

      While pressing down on the shift lever cap, turn it counterclockwise, and then pull to remove the shift lever assembly.

  5. DRAIN MANUAL TRANSMISSION OIL


    1. Remove the drain plug and gasket, and then drain the manual transmission oil.

    2. Install a new gasket and the drain plug.

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

  6. REMOVE FRONT EXHAUST PIPE ASSEMBLY

    Click here

  7. REMOVE TRANSFER CASE LOWER PROTECTOR


    1. Remove the 4 bolts and transfer case lower protector.

  8. REMOVE FRONT PROPELLER SHAFT ASSEMBLY

    Click here

  9. REMOVE PROPELLER SHAFT ASSEMBLY

    Click here

  10. DISCONNECT CLUTCH RELEASE CYLINDER ASSEMBLY


    1. B001DGS

      Remove the 2 bolts and clip, and then disconnect the release cylinder.

  11. REMOVE STARTER ASSEMBLY

    for 2.2 kW Type: Click here

    for 2.7 kW Type: Click here

  12. REMOVE FRONT SUSPENSION MEMBER BRACKET LH

    B001IHE

    1. Remove the 4 bolts and front suspension member bracket LH.

  13. REMOVE FRONT SUSPENSION MEMBER BRACKET RH

    B001IJ3

    1. Remove the 4 bolts and front suspension member bracket RH.

  14. REMOVE NO. 3 FRAME CROSSMEMBER SUB-ASSEMBLY


    1. Support the rear side of the manual transmission with a support stand.

    2. B001F7O

      Remove the 4 bolts from the No. 3 frame crossmember sub-assembly.

    3. B001F13

      Remove the 4 nuts, 4 bolts and No. 3 frame crossmember sub-assembly.

  15. REMOVE REAR NO. 1 ENGINE MOUNTING INSULATOR


    1. B001CTM

      Remove the 4 bolts and rear No. 1 engine mounting insulator from the manual transmission.

  16. DISCONNECT WIRE HARNESS


    1. B001DSR

      Detach the 5 wire harness clamps.

    2. Disconnect the 2 connectors and wire harness.

  17. DISCONNECT TRANSFER AND MANUAL TRANSMISSION BREATHER HOSE SUB-ASSEMBLY


    1. B001CLQ

      Detach the breather hose clamp.

    2. Disconnect the 3 breather hoses.

  18. REMOVE MANUAL TRANSMISSION WITH TRANSFER


    1. B001F8H

      Remove the 9 bolts.

    2. Remove the manual transmission with transfer.

  19. REMOVE TRANSMISSION UPPER COVER SUB-ASSEMBLY

    B001FU9

    1. Remove the 2 bolts and transmission upper cover sub-assembly.

  20. REMOVE TRANSFER ASSEMBLY

    Click here