MANUAL TRANSMISSION ASSEMBLY REMOVAL

CAUTION / NOTICE / HINT

CAUTION:


  • B003QLO

    To prevent burns, do not touch the engine, exhaust pipe or other high temperature components while the engine is hot.

  • B003MKRC03
    *a Object Exceeding Weight Limit of Transmission Jack

    The manual transmission assembly is very heavy. Be sure to follow the procedure described in the repair manual, or the transmission jack may suddenly drop or a part may fall.

PROCEDURE


  1. PRECAUTION

    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.

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  2. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL

    Note

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

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  3. REMOVE SHIFT LEVER KNOB SUB-ASSEMBLY


    1. Remove the shift lever knob sub-assembly from the shift lever.

  4. REMOVE CONSOLE BOX ASSEMBLY

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  5. REMOVE SHIFT LEVER BOOT ASSEMBLY


    1. B003OGY

      Remove the 6 screws, 4 clips and shift lever boot assembly.

  6. REMOVE SHIFT LEVER ASSEMBLY


    1. B003KDY

      Detach the shift lever cap boot from the manual transmission.

    2. Cover the shift lever cap with a cloth.

    3. B003NJPC01
      *1 Shift Lever Cap
      B003OFB Press Down
      B003QYY Counterclockwise
      B003OFV Pull Out

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

  7. REMOVE NO. 1 FLOOR SHIFT BUSH


    1. B003K9W

      Remove the No. 1 floor shift bush from the shift lever assembly.

  8. DRAIN MANUAL TRANSMISSION OIL

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  9. REMOVE NO. 1 ENGINE UNDER COVER ASSEMBLY

  10. REMOVE NO. 2 ENGINE UNDER COVER

  11. REMOVE PROPELLER SHAFT GUARD


    1. B003MAB

      Remove the propeller shaft guard with the 2 bolts.

  12. REMOVE FRONT EXHAUST PIPE ASSEMBLY


  13. REMOVE STARTER ASSEMBLY (for 1KD-FTV)


  14. REMOVE STARTER ASSEMBLY (for 1GD-FTV)


  15. REMOVE NO. 4 CYLINDER BROCK INSULATOR


    1. Remove the No. 4 cylinder block insulator.

  16. REMOVE STIFFENER PLATE LH


    1. B003L13

      Remove the 4 bolts and stiffener plate LH.

  17. REMOVE STIFFENER PLATE RH


    1. B003QFJ

      Remove the 4 bolts and stiffener plate RH.

  18. REMOVE PROPELLER SHAFT WITH CENTER BEARING ASSEMBLY


  19. REMOVE FRONT DIFFERENTIAL CARRIER ASSEMBLY

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  20. DISCONNECT GROUND CABLE


    1. B003POE

      Remove the bolt and disconnect the ground cable.

  21. SUPPORT MANUAL TRANSMISSION ASSEMBLY


    1. B003JQV

      Support the manual transmission with a transmission jack.

      Note


      • Make sure the high transmission jack attachment is centered on the safety stand.

      • Secure the part with a rope, attachment, etc.

  22. REMOVE NO. 3 FRAME CROSSMEMBER SUB-ASSEMBLY


    1. B003QD9

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

    2. B003S3O

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

  23. REMOVE REAR ENGINE MOUNTING INSULATOR


    1. B003PAC

      Remove the 4 bolts and rear engine mounting insulator from the manual transmission assembly.

  24. DISCONNECT WIRE HARNESS


    1. w/ Downhill Assist Control:


      1. B003MNG

        Disconnect the neutral position switch conector.

    2. B003SDG

      w/ Intelligent Manual Transmission Switch:


      1. Detach the 7 wire harness clamps.

      2. Remove the bolt.

      3. Disconnect the 3 connectors and wire harness.

    3. B003QQU

      w/o Intelligent Manual Transmission Switch:


      1. Detach the 5 wire harness clamps.

      2. Remove the bolt.

      3. Disconnect the 2 connectors and wire harness.

  25. REMOVE MANUAL TRANSMISSION ASSEMBLY


    1. B003ROE

      Remove the 5 bolts and manual transmission assembly.

      Note

      As the manual transmission assembly is very heavy, be sure to support it securely.

  26. REMOVE TRANSMISSION BREATHER SUB-ASSEMBLY


    1. B003MZI

      Detach the 4 breather hose clamps and bracket.

    2. Remove the transmission breather sub-assembly from the control shift lever retainer assembly.

    3. B003PPQ

      Remove the 2 bolts and 2 brackets.

  27. REMOVE WIRING HARNESS CLAMP BRACKET


    1. B003N4R

      w/ Intelligent Manual Transmission Switch:


      1. Remove the 8 bolts and 7 wiring harness clamp brackets.

    2. B003NZ4

      w/o Intelligent Manual Transmission Switch:


      1. Remove the 7 bolts and 6 wiring harness clamp brackets.

  28. REMOVE TRANSFER ASSEMBLY

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