MANUAL TRANSMISSION ASSEMBLY INSTALLATION

CAUTION / NOTICE / HINT

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.

PROCEDURE


  1. INSTALL WIRE HARNESS CLAMP BRACKET


    1. B0025U2N01

      except 1TR-FE, 2TR-FE:

      Install the 3 wire harness clamp brackets to the manual transmission unit sub-assembly with the 3 bolts.

      Torque:
      for bolt A
      12.6 N*m  { 128 kgf*cm, 9 ft.*lbf }
      for bolt B
      64 N*m  { 653 kgf*cm, 47 ft.*lbf }
      for bolt C
      37 N*m  { 377 kgf*cm, 27 ft.*lbf }
    2. B0024H5N01

      for 1TR-FE, 2TR-FE:

      Install the 2 wire harness clamp brackets to the manual transmission unit sub-assembly with the 2 bolts.

      Torque:
      for bolt A
      64 N*m  { 653 kgf*cm, 47 ft.*lbf }
      for bolt B
      37 N*m  { 377 kgf*cm, 27 ft.*lbf }

  2. INSTALL TRANSMISSION BREATHER SUB-ASSEMBLY


    1. B0025CA

      Connect the 2 clamps and install the transmission breather sub-assembly.

  3. INSTALL 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. Make sure that the knock pins are not loose, bent, damaged or scratched.

    2. Operate the transmission jack and install the manual transmission unit assembly to the vehicle.

      CAUTION:

      Do not raise the manual transmission unit assembly more than necessary. If the manual transmission unit assembly is raised excessively, the vehicle may also be lifted up.

      Note

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

    3. Align the input shaft with the clutch disc and install the manual transmission unit assembly to the engine.

    4. B0026CKC04
      *A for 1TR-FE, 2TR-FE:
      *B except 1TR-FE, 2TR-FE:
      *1 Transmission Breather Bracket

      for 1TR-FE, 2TR-FE:

      Install the transmission breather bracket and 7 bolts.

      Torque:
      for bolt a
      71.5 N*m  { 729 kgf*cm, 53 ft.*lbf }
      for bolt b
      37.2 N*m  { 379 kgf*cm, 27 ft.*lbf }

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

      Install the transmission breather bracket and 5 bolts.

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

  4. INSTALL STIFFENER PLATE (except 1TR-FE, 2TR-FE)


    1. Install the No. 2 rear end plate.

    2. for 1GD-FTV, 2GD-FTV:


      1. Install the stiffener plate RH with the 4 bolts and connect the wire harness.

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

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

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

    3. for 2KD-FTV:


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

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

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

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

    4. Install the No. 4 cylinder block insulator.

  5. INSTALL MANIFOLD STAY (for 1TR-FE, 2TR-FE)


  6. INSTALL REAR ENGINE MOUNTING INSULATOR


    1. Install the rear engine mounting insulator with the 4 bolts.

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

  7. INSTALL NO. 3 FRAME CROSSMEMBER SUB-ASSEMBLY


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

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

    2. Connect the No. 3 frame crossmember sub-assembly to the rear engine mounting insulator.

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

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


  9. INSTALL STARTER ASSEMBLY (for 2GD-FTV)


  10. INSTALL STARTER ASSEMBLY (for 1TR-FE)


  11. INSTALL STARTER ASSEMBLY (for 2TR-FE)

    Click here

  12. INSTALL STARTER ASSEMBLY (for 2KD-FTV)


  13. CONNECT CLUTCH RELEASE CYLINDER ASSEMBLY


    1. Install the clutch release cylinder assembly with the 2 bolts.

      Torque:
      11.7 N*m  { 119 kgf*cm, 9 ft.*lbf }

  14. CONNECT WIRE HARNESS


    1. B0025OF

      Connect the 2 clamps and connector.

    2. B0028B6

      Connect the ground cable with the bolt.

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

  15. INSTALL FRONT EXHAUST PIPE ASSEMBLY


  16. INSTALL PROPELLER SHAFT WITH CENTER BEARING ASSEMBLY


  17. INSTALL NO. 2 FRAME CROSSMEMBER SUB-ASSEMBLY (for 2WD)


    1. Install the No. 2 frame crossmember sub-assembly with the 4 bolts and 4 nuts.

      Torque:
      50 N*m  { 510 kgf*cm, 37 ft.*lbf }

  18. ADD MANUAL TRANSMISSION OIL

    Click here

  19. INSTALL NO. 3 ENGINE UNDER COVER SUB-ASSEMBLY (for Pre-Runner)

    Torque:
    28 N*m  { 286 kgf*cm, 21 ft.*lbf }

  20. INSTALL NO. 2 ENGINE UNDER COVER (for Pre-Runner)

    Torque:
    28 N*m  { 286 kgf*cm, 21 ft.*lbf }

  21. INSTALL NO. 1 ENGINE UNDER COVER ASSEMBLY (for Pre-Runner)

    Torque:
    for M6 bolt
    11.5 N*m  { 117 kgf*cm, 8 ft.*lbf }
    for M8 bolt
    28 N*m  { 286 kgf*cm, 21 ft.*lbf }

  22. INSTALL NO. 1 ENGINE UNDER COVER (for 2WD)

    Torque:
    28 N*m  { 286 kgf*cm, 21 ft.*lbf }

  23. INSTALL NO. 1 ENGINE UNDER COVER ASSEMBLY (for 2WD)

    Torque:
    for M8 bolt
    28 N*m  { 286 kgf*cm, 21 ft.*lbf }
    for M10 bolt
    50 N*m  { 510 kgf*cm, 37 ft.*lbf }

  24. INSTALL FLOOR SHIFT SHIFT LEVER ASSEMBLY


    1. B00246BC01
      B0068HS MP grease

      Apply MP grease to the tip of the shift lever.

    2. B0025SXC02
      *1 Shift Lever Cap
      *a Press down
      *b Clockwise
      *c 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.

    4. Attach the shift lever cap boot.

  25. INSTALL SHIFT LEVER BOOT ASSEMBLY


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

    2. Install the shift lever cover.

  26. INSTALL CONSOLE BOX ASSEMBLY (w/ Console Box Lid)

    Click here

  27. INSTALL FRONT CONSOLE BOX (w/o Console Box Lid)

    Click here

  28. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

    Note

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

    Click here