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MANUAL TRANSMISSION ASSEMBLY REMOVAL

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CAUTION / NOTICE / HINT

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.

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  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.

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  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)

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  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. B0027JE

      Detach the shift lever cap boot from the manual transmission.

    2. Cover the shift lever cap with a cloth.

    3. 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 FLOOR SHIFT BUSH


    1. B0028TD

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

  8. Click here

    DRAIN MANUAL TRANSMISSION OIL

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  9. Click here

    REMOVE NO. 1 ENGINE UNDER COVER ASSEMBLY

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    REMOVE NO. 2 ENGINE UNDER COVER

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    REMOVE FRONT EXHAUST PIPE ASSEMBLY (for 1GD-FTV)

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    REMOVE FRONT EXHAUST PIPE ASSEMBLY (for 2GD-FTV)

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  13. Click here

    REMOVE FRONT EXHAUST PIPE ASSEMBLY (for 2KD-FTV)

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  14. Click here

    REMOVE STARTER ASSEMBLY (for 1GD-FTV)


    1. for 2.0 kW Type:

      Click here

    2. for 2.2 kW Type:

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  15. Click here

    REMOVE STARTER ASSEMBLY (for 2GD-FTV)


    1. for 2.0 kW Type:

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    2. for 2.2 kW Type:

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    3. for 2.7 kW Type:

      Click here

  16. Click here

    REMOVE STARTER ASSEMBLY (for 2KD-FTV)


    1. for 2.0 kW Type:

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    2. for 2.2 kW Type:

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  17. Click here

    REMOVE NO. 4 CYLINDER BLOCK INSULATOR


    1. Remove the No. 4 cylinder block insulator.

  18. Click here

    REMOVE STIFFENER PLATE LH


    1. B00268Y

      Remove the 4 bolts and stiffener plate LH.

  19. Click here

    REMOVE STIFFENER PLATE RH


    1. B0027BI

      Remove the 4 bolts and stiffener plate RH.

  20. Click here

    REMOVE PROPELLER SHAFT WITH CENTER BEARING ASSEMBLY

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  21. Click here

    DISCONNECT GROUND CABLE


    1. B0028FC

      Remove the bolt and disconnect the ground cable.

  22. Click here

    SUPPORT MANUAL TRANSMISSION ASSEMBLY


    1. B0025E7

      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.

  23. Click here

    REMOVE NO. 3 FRAME CROSSMEMBER SUB-ASSEMBLY


    1. B0024D5

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

    2. B0024SA

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

  24. Click here

    REMOVE REAR ENGINE MOUNTING INSULATOR


    1. B0024KG

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

  25. Click here

    DISCONNECT WIRE HARNESS


    1. A01SILN

      w/ Intelligent Manual Transmission Switch:


      1. Detach the 5 wire harness clamps.

      2. Remove the bolt.

      3. Disconnect the 2 connectors and wire harness.

    2. A01SJNF

      w/o Intelligent Manual Transmission Switch:


      1. Detach the 3 wire harness clamps.

      2. Remove the bolt.

      3. Disconnect the connector and wire harness.

  26. Click here

    REMOVE MANUAL TRANSMISSION ASSEMBLY


    1. B0027CS

      Remove the 5 bolts and manual transmission assembly.

      Note:

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

  27. Click here

    REMOVE TRANSMISSION BREATHER SUB-ASSEMBLY


    1. B0028RP

      Detach the 4 breather hose clamps and bracket.

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

    3. B0028WX

      Remove the 3 bolts and 3 brackets.

  28. Click here

    REMOVE WIRING HARNESS CLAMP BRACKET


    1. B00266D

      w/ Intelligent Manual Transmission Switch:


      1. Remove the 6 bolts and 5 wiring harness clamp brackets.

    2. B0025MK

      w/o Intelligent Manual Transmission Switch:


      1. Remove the 5 bolts and 4 wiring harness clamp brackets.

  29. Click here

    REMOVE EXTENSION HOUSING DUST DEFLECTOR


    1. B0026T4C01
      *a Protective Tape

      Using a screwdriver, pry out the extension housing dust deflector.

      Note:

      Be careful not to damage the extension housing sub-assembly.

      Tip:

      Tape the screwdriver tip before use.