MANUAL TRANSMISSION ASSEMBLY INSTALLATION

PROCEDURE


  1. INSTALL TRANSFER ASSEMBLY

    Click here

  2. INSTALL WIRING HARNESS CLAMP BRACKET


    1. w/ Intelligent Manual Transmission Switch:


      1. B003N4RC01
        *A w/ Intelligent Manual Transmission Switch

        Install the 8 bolts and 7 wiring harness clamp brackets to the manual transmission assembly.

        Torque:
        for bolt A
        13 N*m  { 133 kgf*cm, 10 ft.*lbf }
        for bolt B
        12.6 N*m  { 128 kgf*cm, 9 ft.*lbf }

    2. w/o Intelligent Manual Transmission Switch:


      1. B003NZ4N01

        Install the 7 bolts and 6 wiring harness clamp brackets to the manual transmission assembly.

        Torque:
        for bolt A
        13 N*m  { 133 kgf*cm, 10 ft.*lbf }
        for bolt B
        12.6 N*m  { 128 kgf*cm, 9 ft.*lbf }

  3. INSTALL TRANSMISSION BREATHER SUB-ASSEMBLY


    1. B003PPQ

      Install the 2 bolts and 2 brackets to the manual transmission assembly.

      Torque:
      19 N*m  { 194 kgf*cm, 14 ft.*lbf }
    2. B003MZI

      Install the transmission breather sub-assembly to the control shift lever retainer sub-assembly.

    3. Attach the 4 breather hose clamps.

  4. INSTALL MANUAL TRANSMISSION ASSEMBLY


    1. B003ROE

      Install the manual transmission assembly with the 5 bolts.

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

  5. CONNECT WIRE HARNESS


    1. B003SDG

      w/ Intelligent Manual Transmission Switch:


      1. Attach the 7 wire harness clamps.

      2. Install the bolt.

      3. Connect the 3 connectors and wire harness.

    2. B003QQU

      w/o Intelligent Manual Transmission Switch:


      1. Attach the 5 wire harness clamps.

      2. Install the bolt.

      3. Connect the 2 connectors and wire harness.

    3. w/ Downhill Assist Control:


      1. B003MNG

        Connect the neutral position switch connector.

  6. INSTALL REAR ENGINE MOUNTING INSULATOR


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

      Torque:
      47 N*m  { 479 kgf*cm, 35 ft.*lbf }

  7. INSTALL NO. 3 FRAME CROSSMEMBER SUB-ASSEMBLY


    1. B003S3O

      Install the No. 3 frame crossmember sub-assembly with the 4 nuts and 4 bolts.

      Torque:
      57 N*m  { 581 kgf*cm, 42 ft.*lbf }
    2. B003QD9

      Install the 4 bolts to the No. 3 frame crossmember sub-assembly.

      Torque:
      18.5 N*m  { 189 kgf*cm, 14 ft.*lbf }

  8. CONNECT GROUND CABLE


    1. B003POE

      Connect the ground cable with the bolt.

      Torque:
      19.5 N*m  { 199 kgf*cm, 14 ft.*lbf }

  9. INSTALL FRONT DIFFERENTIAL CARRIER ASSEMBLY

    Click here

  10. INSTALL PROPELLER SHAFT WITH CENTER BEARING ASSEMBLY


  11. INSTALL STIFFENER PLATE LH


    1. Install the stiffener plate LH with the 4 bolts.

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

  12. INSTALL STIFFENER PLATE RH


    1. Install the stiffener plate RH with the 4 bolts.

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

  13. INSTALL NO. 4 CYLINDER BROCK INSULATOR


    1. Install the No. 4 cylinder block insulator.

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


  15. INSTALL STARTER ASSEMBLY (for 1KD-FTV)


  16. INSTALL FRONT EXHAUST PIPE ASSEMBLY


  17. INSTALL PROPELLER SHAFT GUARD


    1. Install the front propeller shaft guard with the 2 bolts.

      Torque:
      36.2 N*m  { 369 kgf*cm, 27 ft.*lbf }

  18. ADD MANUAL TRANSMISSION OIL

    Click here

  19. INSTALL NO. 2 ENGINE UNDER COVER

    Click here

  20. INSTALL NO. 1 ENGINE UNDER COVER ASSEMBLY

    Click here

  21. INSTALL NO. 1 FLOOR SHIFT BUSH


    1. Install the No. 1 floor shift bush to the shift lever assembly.

  22. INSTALL SHIFT LEVER ASSEMBLY


    1. B003J78C01
      B003R2S MP grease

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

    2. B003RD1C01
      *1 Shift Lever Cap
      B003OFB Press Down
      B003QYY Clockwise
      B003OFV Lock

      Cover the shift lever cap with a cloth.

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

  23. INSTALL SHIFT LEVER BOOT ASSEMBLY


    1. Install the shift lever boot assembly with the 6 screws and 4 clips.

  24. INSTALL CONSOLE BOX ASSEMBLY

    Click here

  25. INSTALL SHIFT LEVER KNOB SUB-ASSEMBLY


    1. Install the shift lever knob sub-assembly to the shift lever.

  26. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

    Note

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

    Click here