MANUAL TRANSMISSION ASSEMBLY(for 1GD-FTV) INSTALLATION

PROCEDURE


  1. INSTALL TRANSFER ASSEMBLY

    Click here

  2. INSTALL TRANSMISSION UPPER COVER SUB-ASSEMBLY


    1. B001FU9

      Install the transmission upper cover sub-assembly with the 2 bolts.

      Torque:
      12 N*m  { 117 kgf*cm, 8 ft.*lbf }

  3. INSTALL 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:

      Install the manual transmission with transfer with the 9 bolts.

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

    2. w/ Urea SCR System:

      Install the manual transmission with transfer with the 9 bolts and wire harness bracket.

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

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


    1. B001HZZ

      Connect the 3 breather hoses.

    2. Attach the breather hose clamp.

  5. CONNECT WIRE HARNESS


    1. B001DSR

      Attach the 5 wire harness clamps.

    2. Connect the 2 connectors and wire harness.

  6. INSTALL REAR NO. 1 ENGINE MOUNTING INSULATOR


    1. B001CTM

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

      Torque:
      73 N*m  { 739 kgf*cm, 54 ft.*lbf }

  7. INSTALL FRONT ENGINE MOUNTING INSULATOR RH


    1. B001CK6

      Install the front engine mounting insulator RH with the bolt.

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

  8. INSTALL NO. 3 FRAME CROSSMEMBER SUB-ASSEMBLY


    1. B001F5U

      w/ Urea SCR System:

      Remove the bolt 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 install the fixing bolt to the No. 3 frame crossmember sub-assembly. Do not raise it any higher.

    2. B001F13

      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 }
    3. B001F4A

      w/ Urea SCR System:

      Connect the urea tank sub-assembly to the No. 3 frame crossmember sub-assembly with the 2 bolts.

      Torque:
      14 N*m  { 146 kgf*cm, 11 ft.*lbf }
    4. B001F7O

      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 (w/o Urea SCR System)


    1. B001IHE

      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 LH (w/ Urea SCR System)


    1. B001GRY

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

      Torque:
      33 N*m  { 337 kgf*cm, 24 ft.*lbf }

  11. INSTALL FRONT SUSPENSION MEMBER BRACKET RH


    1. B001IJ3

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

      Torque:
      33 N*m  { 337 kgf*cm, 24 ft.*lbf }

  12. INSTALL STARTER ASSEMBLY (w/o Urea SCR System)


  13. CONNECT STARTER ASSEMBLY (w/ Urea SCR System)


    1. for 2.0 kW Type:

      Connect the starter assembly.


      1. B001CWM

        Connect the starter assembly with the 2 bolts.

        Torque:
        68 N*m  { 693 kgf*cm, 50 ft.*lbf }

      2. Connect the starter wire with the nut.

        Torque:
        9.8 N*m  { 100 kgf*cm, 87 in.*lbf }

      3. Connect the starter connector.

      4. Close the terminal cap.

    2. for 2.7 kW Type:

      Connect the starter assembly.


      1. B001DXE

        Connect the starter assembly with the 2 bolts.

        Torque:
        68 N*m  { 693 kgf*cm, 50 ft.*lbf }
      2. B001DW6

        Connect the starter wire with the nut.

        Torque:
        21 N*m  { 215 kgf*cm, 16 ft.*lbf }

      3. Connect the starter connector.

      4. Close the terminal cap.

  14. INSTALL FRONT NO. 1 FENDER APRON TO FRAME SEAL LH

    Click here

  15. INSTALL CLUTCH RELEASE CYLINDER ASSEMBLY

    Click here

  16. INSTALL CLUTCH RELEASE CYLINDER TO FLEXIBLE HOSE TUBE


    1. B001CAD

      Install the clutch flexible hose bracket with the 2 bolts.

      Torque:
      19 N*m  { 194 kgf*cm, 14 ft.*lbf }
    2. B001ICUE02

      Temporarily install the clutch release cylinder to flexible hose tube with the 2 bolts, 3 nuts and a new clip.

    3. Tighten the labeled A.

      Torque:
      19 N*m  { 194 kgf*cm, 14 ft.*lbf }

    4. Tighten the labeled B.

      Torque:
      15 N*m  { 155 kgf*cm, 11 ft.*lbf }

  17. INSTALL PROPELLER SHAFT ASSEMBLY

    Click here

  18. INSTALL FRONT PROPELLER SHAFT ASSEMBLY

    Click here

  19. INSTALL OIL PAN INSULATOR


    1. B001EYY

      Install oil pan insulator with the 2 bolts.

      Torque:
      18 N*m  { 184 kgf*cm, 13 ft.*lbf }

  20. CONNECT WIRE HARNESS


    1. B001DS6

      Attach the 2 wire harness clamps and connect the wire harness.

  21. INSTALL WIRE HARNESS CLAMP BRACKET (w/ Urea SCR System)


    1. B001CN6

      Install the wire harness clamp bracket with the bolt.

      Torque:
      13 N*m  { 131 kgf*cm, 9 ft.*lbf }
    2. B001I9D

      Attach the 3 wire harness clamps and connect the wire harness.

  22. 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 }

  23. INSTALL FRONT EXHAUST PIPE ASSEMBLY

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  24. ADD MANUAL TRANSMISSION OIL

  25. INSPECT MANUAL TRANSMISSION OIL

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  26. INSTALL SHIFT LEVER ASSEMBLY

    B001HW4

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

      Text in Illustration
      B001CHY MP Grease

    2. Cover the shift lever cap with a cloth.

    3. B001CQRE05
      Text in Illustration
      *1 Shift Lever Cap
      *a Press down
      *b Clockwise
      *c Lock

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

    4. Attach the shift lever cap boot.

  27. INSTALL NO. 1 SHIFT AND SELECT LEVER BOOT


    1. Install the No. 1 shift and select lever boot with the 4 screws.

  28. INSTALL CONSOLE BOX ASSEMBLY


  29. FILL RESERVOIR WITH BRAKE FLUID

    Click here

  30. BLEED CLUTCH LINE

    Click here

  31. INSPECT FLUID LEVEL IN RESERVOIR

    Click here

  32. INSPECT FOR BRAKE FLUID LEAK FROM CLUTCH LINE

  33. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

    Note

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