MANUAL TRANSMISSION ASSEMBLY(for 1GD-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


  3. REMOVE NO. 1 SHIFT AND SELECT LEVER BOOT


    1. B001EZL

      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 BRAKE FLUID FROM CLUTCH LINE

  6. 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 }

  7. REMOVE FRONT EXHAUST PIPE ASSEMBLY

    Click here

  8. REMOVE TRANSFER CASE LOWER PROTECTOR


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

  9. REMOVE WIRE HARNESS CLAMP BRACKET (w/ Urea SCR System)


    1. B001I9D

      Detach the 3 wire harness clamps and disconnect the wire harness.

    2. B001CN6

      Remove the bolt and wire harness clamp bracket.

  10. DISCONNECT WIRE HARNESS (w/ Urea SCR System)


    1. B001DS6

      Detach the 2 wire harness clamps and disconnect the wire harness.

  11. REMOVE OIL PAN INSULATOR


    1. B001EYY

      Remove the 2 bolts and oil pan insulator.

  12. REMOVE FRONT PROPELLER SHAFT ASSEMBLY

    Click here

  13. REMOVE PROPELLER SHAFT ASSEMBLY

    Click here

  14. REMOVE CLUTCH RELEASE CYLINDER TO FLEXIBLE HOSE TUBE


    1. B001ICU

      Remove the 2 bolts, 3 nut, clip and clutch release cylinder to flexible hose tube.

    2. B001CAD

      Remove the 2 bolts and clutch flexible hose bracket.

  15. REMOVE CLUTCH RELEASE CYLINDER ASSEMBLY

    Click here

  16. REMOVE FRONT NO. 1 FENDER APRON TO FRAME SEAL LH (w/ Urea SCR System)

    Click here

  17. DISCONNECT STARTER ASSEMBLY (w/ Urea SCR System)


    1. for 2.0 kW Type:

      Disconnect the starter.


      1. Open the terminal cap.

      2. B001GV5

        Remove the nut and disconnect the starter wire.

      3. Disconnect the starter connector.

      4. Remove the 2 bolts and disconnect the starter assembly.

    2. for 2.7 kW Type:

      Disconnect the starter.


      1. B001DW6

        Open the terminal cap.

      2. Remove the nut and disconnect the starter wire.

      3. Disconnect the starter connector.

      4. B001DXE

        Remove the 2 bolts and disconnect the starter assembly.

  18. REMOVE STARTER ASSEMBLY (w/o Urea SCR System)


  19. REMOVE FRONT SUSPENSION MEMBER BRACKET LH


    1. B001IHE

      Remove the 4 bolts and front suspension member bracket LH.

  20. REMOVE FRONT SUSPENSION MEMBER BRACKET LH (w/ Urea SCR System)


    1. B001GRY

      Remove the 4 bolts and front suspension member bracket LH.

  21. REMOVE FRONT SUSPENSION MEMBER BRACKET RH

    B001IJ3

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

  22. 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. B001EWJ

      w/ Urea SCR System:

      Remove the 2 bolts as shown in the illustration, raise the urea tank sub-assembly and hold it in position.

      Tech Tips

      Only raise the urea tank enough to remove the fixing bolts on the No. 3 frame crossmember sub-assembly. Do not raise it any higher.

    4. B001F13

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

    5. B001GYV

      w/ Urea SCR System:

      Temporarily install the urea tank sub-assembly with the bolt as shown in the illustration.

  23. REMOVE FRONT ENGINE MOUNTING INSULATOR RH


    1. B001CK6

      Remove the bolt and front engine mounting insulator RH.

  24. REMOVE REAR NO. 1 ENGINE MOUNTING INSULATOR


    1. B001CTM

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

  25. DISCONNECT WIRE HARNESS


    1. B001DSR

      Detach the 5 wire harness clamps.

    2. Disconnect the 2 connectors and wire harness.

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


    1. B001CLQ

      Detach the breather hose clamp.

    2. Disconnect the 3 breather hoses.

  27. REMOVE MANUAL TRANSMISSION WITH TRANSFER


    1. B001CUSE01
      Text in Illustration
      *A w/o Urea SCR System
      *B w/ Urea SCR System
      *1 Wire Harness Bracket

      w/o Urea SCR System:

      Remove the 9 bolts.

    2. w/ Urea SCR System:

      Remove the 9 bolts and wire harness bracket.

    3. Remove the manual transmission with transfer.

  28. REMOVE TRANSMISSION UPPER COVER SUB-ASSEMBLY

    B001FU9

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

  29. REMOVE TRANSFER ASSEMBLY

    Click here