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MANUAL TRANSMISSION ASSEMBLY REMOVAL

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CAUTION / NOTICE / HINT

The necessary procedures (adjustment, calibration, initialization, or registration) that must be performed after parts are removed, installed, or replaced during the manual transmission assembly removal/installation are shown below.

Table 1. Necessary Procedure After Parts Removed/Installed/Replaced
Replacement Part or Procedure Necessary Procedures Effects/Inoperative when not Performed Link

  • for 1TR-FE:

  • Gas leak from exhaust system is repaired

 Inspection After Repair Poor idle, engine start, etc.

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  • for 2TR-FE:

  • Gas leak from exhaust system is repaired

 Inspection After Repair Poor idle, engine start, etc.

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CAUTION:

  • B0068W8

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

  • B00281GC03
    *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.

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PROCEDURE


  1. Click here

    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.

    Click here

  2. Click here

    DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL

    Note:

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

    Click here

  3. Click here

    REMOVE CONSOLE BOX ASSEMBLY (w/ Console Box Lid)

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  4. Click here

    REMOVE FRONT CONSOLE BOX (w/o Console Box Lid)

    Click here

  5. Click here

    REMOVE SHIFT LEVER BOOT ASSEMBLY


    1. B00245Z

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

  6. Click here

    REMOVE FLOOR SHIFT SHIFT LEVER ASSEMBLY


    1. Remove the shift lever cover.

    2. B0027JE

      Detach the shift lever cap boot from the manual transmission.

    3. Cover the shift lever cap with a cloth.

    4. B0026ANC02
      *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.

  7. Click here

    REMOVE NO. 1 ENGINE UNDER COVER ASSEMBLY

  8. Click here

    REMOVE NO. 1 ENGINE UNDER COVER

  9. Click here

    DRAIN MANUAL TRANSMISSION OIL


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

    2. Install a new gasket and the drain plug sub-assembly.

      37 N*m 377 kgf*cm 27 ft.*lbf
  10. Click here

    REMOVE NO. 2 FRAME CROSSMEMBER SUB-ASSEMBLY


    1. Remove the 4 bolts, 4 nuts and No. 2 frame crossmember sub-assembly.

  11. Click here

    REMOVE PROPELLER SHAFT WITH CENTER BEARING ASSEMBLY

    Click here

  12. Click here

    REMOVE FRONT EXHAUST PIPE ASSEMBLY


    1. for 1GD-FTV:

      Click here

    2. for 2GD-FTV:

      Click here

    3. for 1TR-FE:

      Click here

    4. for 2TR-FE:

      Click here

    5. for 2KD-FTV:

      Click here

  13. Click here

    DISCONNECT WIRE HARNESS


    1. B0025OF

      Disconnect the 2 clamps and connector.

    2. B0028B6

      Remove the bolt and disconnect the ground cable.

  14. Click here

    DISCONNECT CLUTCH RELEASE CYLINDER ASSEMBLY

    Click here

  15. Click here

    REMOVE STARTER ASSEMBLY (for 1GD-FTV)


    1. for 2.0 kW Type:

      Click here

    2. for 2.2 kW Type:

      Click here

  16. Click here

    REMOVE STARTER ASSEMBLY (for 2GD-FTV)


    1. for 2.0 kW Type:

      Click here

    2. for 2.2 kW Type:

      Click here

  17. Click here

    REMOVE STARTER ASSEMBLY (for 1TR-FE)

    Click here

  18. Click here

    REMOVE STARTER ASSEMBLY (for 2TR-FE)

    Click here

  19. Click here

    REMOVE STARTER ASSEMBLY (for 2KD-FTV)


    1. for 2.0 kW Type:

      Click here

    2. for 2.2 kW Type:

      Click here

  20. Click here

    SUPPORT MANUAL TRANSMISSION ASSEMBLY


    1. B0026Y8

      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.

  21. Click here

    REMOVE NO. 3 FRAME CROSSMEMBER SUB-ASSEMBLY


    1. B0026GQ

      Remove the 4 set bolts of the rear engine mounting insulator.

    2. B0024SA

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

  22. Click here

    REMOVE REAR ENGINE MOUNTING INSULATOR


    1. B0024KK

      Remove the 4 bolts and rear engine mounting insulator.

  23. Click here

    REMOVE MANIFOLD STAY (for 1TR-FE, 2TR-FE)


    1. for 1TR-FE:

      Click here

    2. for 2TR-FE:

      Click here

  24. Click here

    REMOVE STIFFENER PLATE (except 1TR-FE, 2TR-FE)


    1. Remove the No. 4 cylinder block insulator.

    2. B0026I3

      for 1GD-FTV, 2GD-FTV:


      1. Remove the 4 bolts and stiffener plate RH and disconnect the wire harness.

      2. Remove the 4 bolts and stiffener plate LH.

    3. B002694

      for 2KD-FTV:


      1. Remove the 4 bolts and stiffener plate RH.

      2. Remove the 4 bolts and stiffener plate LH.

    4. Remove the No. 2 rear end plate.

  25. Click here

    REMOVE MANUAL TRANSMISSION UNIT ASSEMBLY

    CAUTION:

    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.


    1. B0026YOC01
      *A for 1TR-FE, 2TR-FE:
      *B except 1TR-FE, 2TR-FE:

      for 1TR-FE, 2TR-FE:

      Remove the 7 bolts, transmission breather bracket and manual transmission unit assembly.

    2. except 1TR-FE, 2TR-FE:

      Remove the 5 bolts, transmission breather bracket and manual transmission unit assembly.

    3. Operate the transmission jack and slowly remove the manual transmission unit assembly from the vehicle.

      Note:

      Make sure that the manual transmission unit assembly is clear of all wiring and hoses.

  26. Click here

    REMOVE TRANSMISSION BREATHER SUB-ASSEMBLY


    1. B0025CA

      Disconnect the 2 clamps and remove the transmission breather sub-assembly.

  27. Click here

    REMOVE WIRE HARNESS CLAMP BRACKET


    1. B0025U2

      except 1TR-FE, 2TR-FE:

      Remove the 3 bolts and 3 wire harness clamp brackets from the manual transmission unit assembly.

    2. B0024H5

      for 1TR-FE, 2TR-FE:

      Remove the 2 bolts and 2 wire harness clamp brackets from the manual transmission unit assembly.