MANUAL TRANSMISSION ASSEMBLY REMOVAL


  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 Click here

  2. 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. REMOVE UPPER CONSOLE PANEL SUB-ASSEMBLY

    w/o Console Box Lid Click here

    w/ Cool Box Click here

    w/o Cool Box Click here

  4. REMOVE SHIFT LEVER BOOT ASSEMBLY

    A0157IJ

    1. Remove the 4 screws, shift lever retainer and shift lever boot.

  5. REMOVE FLOOR SHIFT LEVER ASSEMBLY

    A0157RFE01

    1. Cover the shift lever cap with a cloth.

    2. Press down on the shift lever cap and rotate it counterclockwise to remove it.

    3. Pull out the shift lever.

  6. REMOVE NO. 1 ENGINE COVER SUB-ASSEMBLY (w/ Intercooler)


    1. A015BEI

      Remove the 2 nuts and No. 1 engine cover.

  7. REMOVE INTERCOOLER ASSEMBLY (w/ Intercooler)


    1. A0158Z5

      Loosen the No. 1 air hose clamp.

    2. A015BZV

      Loosen the No. 2 air hose clamp.

    3. A0155JY

      Disconnect the turbo pressure sensor connector, intake air temperature sensor connector and vacuum hose.

    4. A015DCM

      Remove the 6 nuts, 2 bolts and intercooler.

    5. Remove the 2 gaskets from the air tube LH and RH.

  8. REMOVE NO. 2 COOL AIR INLET (w/o Intercooler)


    1. A015B0X

      Loosen the No. 2 air hose clamp.

    2. A015A93

      Remove the 3 nuts, bolt and No. 2 cool air inlet.

    3. Remove the gasket from the air tube LH.

  9. DRAIN CLUTCH FLUID

  10. REMOVE CLUTCH HOSE (for 1VD-FTV)


    1. A015C2Z

      Disconnect the 2 flexible hose tubes from the clutch hose with a 10 mm union nut wrench while holding the flexible hose with a wrench.

      Note


      • Do not bend or damage the flexible hose tubes.

      • Do not allow any foreign matter such as dirt and dust to enter the flexible hose tubes from the connecting point.

    2. Remove the 2 clips.

    3. A0159T9

      Remove the bolt and clutch hose.

  11. REMOVE AIR TUBE SUB-ASSEMBLY LH (for 1VD-FTV)


    1. A015B7A

      Loosen the hose clamp.

    2. Remove the air tube from the throttle body.

  12. REMOVE TUBE CONNECTOR TO FLEXIBLE HOSE TUBE (for 1VD-FTV)


    1. A015APM

      Using a 10 mm union nut wrench, disconnect the tube connector to flexible hose tube from the clutch tube to release cylinder 2 way.

      Note


      • Do not bend or damage the flexible hose tube.

      • Do not allow any foreign matter such as dirt and dust to enter the flexible hose tube from the connecting point.

    2. A0155T9

      Remove the 2 bolts and tube connector to flexible hose tube.

  13. REMOVE TRANSFER HEAT INSULATOR


    1. A01593H

      Remove the 4 bolts and insulator.

  14. REMOVE TRANSFER DYNAMIC DAMPER (for 1VD-FTV)

    A0156Y8

    1. Remove the 2 bolts and transfer dynamic damper.

  15. REMOVE LOWER TRANSFER CASE PROTECTOR

    A015DHZ

    1. Remove the 7 bolts and lower transfer case protector.

  16. DRAIN MANUAL TRANSMISSION OIL

    A0156UO

    1. Remove the drain plug and gasket and then drain the manual transmission oil.

    2. A0158KM

      Remove the filler plug and gasket.

    3. Install a new gasket and the drain plug.

      Torque:
      37 N*m  { 380 kgf*cm, 27 ft.*lbf }

  17. DRAIN TRANSFER OIL


    1. A0156Y8

      except 1GR-FE:

      Remove the 2 bolts and transfer dynamic damper.

    2. A01593H

      Remove the 4 bolts and transfer heat insulator.

    3. A015DHZ

      Remove the 7 bolts and lower transfer case protector.

    4. A015BBP

      Remove the filler plug and gasket.

    5. A015AJZ

      Remove the drain plug and gasket, and drain the transfer oil.

  18. REMOVE PROPELLER SHAFT ASSEMBLY

    Click here

  19. REMOVE FRONT PROPELLER SHAFT ASSEMBLY

    Click here

  20. REMOVE EXHAUST PIPE (for 1GR-FE)

    Click here

  21. REMOVE EXHAUST PIPE (for 1VD-FTV)

    w/o DPF: Click here

    w/ DPF: Click here

  22. REMOVE MANIFOLD STAY (for 1GR-FE)


    1. A015A0B

      Remove the 3 bolts and manifold stay.

  23. REMOVE NO. 2 MANIFOLD STAY (for 1GR-FE)


    1. A0157CN

      Remove the 3 bolts and No. 2 manifold stay.

  24. REMOVE STARTER ASSEMBLY (for 1GR-FE)

    Click here

  25. REMOVE NO. 2 FRAME CROSSMEMBER SUB-ASSEMBLY


    1. Support the transmission with a transmission jack. Lift the transmission slightly from the crossmember.

    2. A015D6E

      Remove the 4 bolts of the rear engine mounting insulator.

    3. A015793

      Remove the 4 bolts, 4 nuts, 4 washers and frame crossmember.

  26. REMOVE REAR NO. 1 ENGINE MOUNTING INSULATOR


    1. A015DOH

      Remove the 4 bolts and engine mounting insulator.

  27. REMOVE TRANSFER BREATHER HOSE SUB-ASSEMBLY (for 1GR-FE)


    1. A015DDX

      Disconnect the breather hose from the transfer and actuator, and disconnect the 2 clamps.

    2. A015BLT

      Disconnect the 5 clamps.

    3. A0155FQ

      Disconnect the 2 breather hoses from the bracket.

  28. REMOVE TRANSFER BREATHER HOSE SUB-ASSEMBLY (for 1VD-FTV)


    1. A015DDX

      Disconnect the breather hose from the transfer and actuator, and disconnect the 2 clamps.

    2. A0158MC

      Disconnect the 3 clamps.

    3. A0155EK

      Disconnect the 3 breather hoses from the bracket.

    4. Remove the bolt and disconnect the bracket from the transmission.

  29. DISCONNECT WIRE HARNESS (for 1GR-FE)


    1. A015692

      Disconnect the 2 connectors and 3 clamps.

    2. A0157BE

      Remove the bolt and disconnect the ground cable.

    3. Tilt the transmission downward.

      Note

      Make sure the cooling fan does not contact the fan shroud.

    4. A015A3HE01

      Remove the 2 bolts.

    5. Disconnect the back-up light switch connector.

    6. Disconnect the 6 clamps.

  30. DISCONNECT WIRE HARNESS (for 1VD-FTV)


    1. A015692

      Disconnect the 2 connectors and 3 clamps.

    2. A0157BE

      Remove the bolt and disconnect the ground cable.

    3. Tilt the transmission downward.

      Note

      Make sure the cooling fan does not contact the fan shroud.

    4. A01580I

      Disconnect the shift position switch connector.

    5. Disconnect the back-up light switch connector.

    6. Disconnect the 5 clamps.

  31. REMOVE NO. 1 CLUTCH HOUSING COVER

    A0159QS

    1. Remove the 3 bolts and clutch housing cover.

  32. REMOVE CLUTCH RELEASE CYLINDER TO ACCUMULATOR TUBE

    A015DLM

    1. Using a union nut wrench, disconnect the tube.

      Tech Tips

      Use a container to catch the fluid.

    2. Remove the 2 bolts and tube.

  33. REMOVE CLUTCH ACCUMULATOR ASSEMBLY

    A015CK3

    1. Using a union nut wrench, disconnect the flexible hose tube.

      Tech Tips

      Use a container to catch the fluid.

    2. A015677

      Remove the 3 bolts and clutch accumulator.

  34. REMOVE CLUTCH RELEASE CYLINDER ASSEMBLY

    A0159TA

    1. Remove the 2 bolts and pull out the clutch release cylinder.

  35. REMOVE CLUTCH RELEASE CYLINDER TO FLEXIBLE HOSE TUBE

    A015D1BE01

    1. Remove the 3 bolts and flexible hose tube.

  36. REMOVE OIL PAN COVER (for 1VD-FTV)

    A015CDP

    1. Remove the 2 bolts and oil pan cover.

  37. REMOVE MANUAL TRANSMISSION WITH TRANSFER (for 1GR-FE)

    A0159VW

    1. Remove the 9 bolts and manual transmission with transfer.

  38. REMOVE MANUAL TRANSMISSION WITH TRANSFER (for 1VD-FTV)

    A0157CI

    1. Remove the 10 bolts and manual transmission with transfer.

  39. REMOVE TRANSFER ASSEMBLY


    1. A015AJWE01

      Remove the 8 transfer adaptor rear mounting bolts.

    2. Pull the transfer straight up and remove it from the transmission.

      Note

      Take care not to damage the adaptor oil seal with the transfer input shaft spline.

  40. REMOVE CLUTCH RELEASE FORK SUB-ASSEMBLY

    A0157SL

    1. Remove the clutch release fork with the clutch release bearing from the transmission unit.

    2. Remove the release fork support from the transmission unit.

    3. A0159CY

      Remove the clip and release bearing from the clutch release fork.