MANUAL TRANSMISSION ASSEMBLY INSTALLATION


  1. INSTALL CLUTCH RELEASE FORK SUB-ASSEMBLY

    A0156S1E02

    1. Apply release hub grease to the release fork, release bearing, push rod contact point and pivot points shown in the illustration.

      Grease
      Toyota Genuine Release Hub Grease or equivalent
    2. A015CU3E01

      Apply clutch spline grease to the input shaft spline.

      Grease
      Toyota Genuine Clutch Spline Grease or equivalent
    3. A0159CY

      Install the release bearing to the clutch release fork with the clip.

    4. A0157SL

      Install the release fork support to the transmission unit.

      Torque:
      47 N*m  { 480 kgf*cm, 35 ft.*lbf }

    5. Install the clutch release fork with the clutch release bearing to the transmission unit.

      Tech Tips

      After installation, move the fork back and forth to check that the release bearing slides smoothly.

  2. INSTALL TRANSFER ASSEMBLY


    1. A015AJWE01

      Install the transfer with the 8 bolts.

      Torque:
      40 N*m  { 408 kgf*cm, 30 ft.*lbf }

      Note

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

  3. INSTALL MANUAL TRANSMISSION WITH TRANSFER (for 1GR-FE)

    A0159VWE01

    Note

    Check that the 2 straight pins are attached to the engine side.


    1. Install the manual transmission with transfer with the 9 bolts.

      Torque:
      for bolt A
      72 N*m  { 730 kgf*cm, 53 ft.*lbf }
      for bolt B
      37 N*m  { 380 kgf*cm, 28 ft.*lbf }
      Bolt Length
      Item Length
      Bolt A 50 mm (1.97 in.)
      Bolt B 45 mm (1.77 in.)

  4. INSTALL MANUAL TRANSMISSION WITH TRANSFER (for 1VD-FTV)

    A0157CIE01

    Note

    Check that the 2 straight pins are attached to the engine side.


    1. Install the manual transmission with transfer with the 10 bolts.

      Torque:
      for bolt A and B
      72 N*m  { 730 kgf*cm, 53 ft.*lbf }
      for bolt C
      39 N*m  { 400 kgf*cm, 29 ft.*lbf }
      Bolt Length
      Item Length
      Bolt A 45 mm (1.77 in.)
      Bolt B 50 mm (1.97 in.)
      Bolt C 70 mm (2.76 in.)

  5. INSTALL OIL PAN COVER (for 1VD-FTV)

    A015CDP

    1. Install the oil pan cover with the 2 bolts.

      Torque:
      21 N*m  { 214 kgf*cm, 15 ft.*lbf }

  6. INSTALL CLUTCH RELEASE CYLINDER TO FLEXIBLE HOSE TUBE

    A015D1BE01

    1. Install the flexible hose tube with the 3 bolts.

      Torque:
      20 N*m  { 204 kgf*cm, 15 ft.*lbf }

  7. INSTALL CLUTCH RELEASE CYLINDER ASSEMBLY

    A0159TA

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

      Torque:
      12 N*m  { 120 kgf*cm, 9 ft.*lbf }

  8. INSTALL CLUTCH ACCUMULATOR ASSEMBLY

    A015677

    1. Install the clutch accumulator with the 3 bolts.

      Torque:
      12 N*m  { 120 kgf*cm, 9 ft.*lbf }
    2. A01568S

      Using a union nut wrench, connect the flexible hose tube.

      Torque:
      15 N*m  { 155 kgf*cm, 11 ft.*lbf }

      Note

      Use the formula to calculate special torque values for situations where a union nut wrench is combined with a torque wrench Click here.

  9. INSTALL CLUTCH RELEASE CYLINDER TO ACCUMULATOR TUBE

    A015AE6

    1. Using a union nut wrench, connect the tube to the clutch accumulator and release cylinder.

      Torque:
      16 N*m  { 158 kgf*cm, 11 ft.*lbf }

      Note

      Use the formula to calculate special torque values for situations where a union nut wrench is combined with a torque wrench Click here.

    2. Install the tube with the 2 bolts.

      Torque:
      12 N*m  { 120 kgf*cm, 9 ft.*lbf }

  10. INSTALL NO. 1 CLUTCH HOUSING COVER

    A0159QS

    1. Install the housing cover with the 3 bolts.

      Torque:
      12 N*m  { 120 kgf*cm, 9 ft.*lbf }

  11. CONNECT WIRE HARNESS (for 1GR-FE)

    A015A3HE01

    1. Connect the 6 clamps.

    2. Connect the back-up light switch connector.

    3. Install the 2 bolts.

      Torque:
      for LH side
      60 N*m  { 612 kgf*cm, 44 ft.*lbf }
      for RH side
      29 N*m  { 296 kgf*cm, 21 ft.*lbf }
    4. A0157BE

      Connect the ground cable with the bolt.

      Torque:
      8.0 N*m  { 82 kgf*cm, 71 in.*lbf }
    5. A015692

      Connect the 2 connectors and 3 clamps.

  12. CONNECT WIRE HARNESS (for 1VD-FTV)

    A01580I

    1. Connect the 5 clamps.

    2. Connect the back-up light switch connector.

    3. Connect the shift position switch connector.

    4. A0157BE

      Connect the ground cable with the bolt.

      Torque:
      8.0 N*m  { 82 kgf*cm, 71 in.*lbf }
    5. A015692

      Connect the 2 connectors and 3 clamps.

  13. INSTALL TRANSFER BREATHER HOSE SUB-ASSEMBLY (for 1GR-FE)

    A0155FQ

    1. Connect the 2 breather hoses to the bracket.

    2. A015BLT

      Connect the 5 clamps.

    3. A015DDX

      Connect the breather hose to the transfer and actuator, and attach the 2 clamps.

  14. INSTALL TRANSFER BREATHER HOSE SUB-ASSEMBLY (for 1VD-FTV)

    A0155EK

    1. Install the bracket with the bolt.

    2. Connect the 3 breather hoses to the bracket.

    3. A0158MC

      Connect the 3 clamps.

    4. A015DDX

      Connect the breather hose to the transfer and actuator, and attach the 2 clamps.

  15. INSTALL REAR NO. 1 ENGINE MOUNTING INSULATOR

    A015DOH

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

      Torque:
      59 N*m  { 602 kgf*cm, 44 ft.*lbf }

  16. INSTALL NO. 2 FRAME CROSSMEMBER SUB-ASSEMBLY

    A015D6E

    1. Install the frame crossmember to the rear engine mounting insulator with the 4 bolts.

      Torque:
      37 N*m  { 377 kgf*cm, 27 ft.*lbf }
    2. A015793

      Install the frame crossmember to the vehicle body with the 4 bolts, 4 washers and 4 nuts.

      Torque:
      110 N*m  { 1,122 kgf*cm, 81 ft.*lbf }

  17. INSTALL STARTER ASSEMBLY (for 1GR-FE)

    Click here

  18. INSTALL NO. 2 MANIFOLD STAY (for 1GR-FE)


    1. Install the No. 2 manifold stay with the 3 bolts.

      Torque:
      40 N*m  { 408 kgf*cm, 30 ft.*lbf }

  19. INSTALL MANIFOLD STAY (for 1GR-FE)


    1. Install the manifold stay with the 3 bolts.

      Torque:
      40 N*m  { 408 kgf*cm, 30 ft.*lbf }

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

    Click here

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

    w/o DPF: Click here

    w/ DPF: Click here

  22. INSTALL FRONT PROPELLER SHAFT ASSEMBLY

    Click here

  23. INSTALL PROPELLER SHAFT ASSEMBLY

    Click here

  24. ADD MANUAL TRANSMISSION OIL

  25. INSPECT TRANSMISSION OIL


    1. Park the vehicle in a level place.

    2. A015750E33

      Check that the oil level is within 5 mm (0.196 in.) of the lowest point of the transmission filler plug opening.

      Note


      • Problems may occur when the oil level is too high or low.

      • After replacing the oil, drive the vehicle and check the oil level again.

    3. Inspect for oil leaks when the oil level is low.

    4. A0158KM

      Install a new gasket and the filler plug.

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

  26. INSTALL LOWER TRANSFER CASE PROTECTOR

    A015DHZ

    1. Install the lower transfer case protector with the 7 bolts.

      Torque:
      14 N*m  { 139 kgf*cm, 10 ft.*lbf }

  27. INSTALL TRANSFER DYNAMIC DAMPER (for 1VD-FTV)

    A0156Y8

    1. Install the transfer dynamic damper with the 2 bolts.

      Torque:
      12 N*m  { 122 kgf*cm, 9 ft.*lbf }

  28. INSTALL TRANSFER HEAT INSULATOR


    1. A01593H

      Install the insulator with the 4 bolts.

      Torque:
      30 N*m  { 306 kgf*cm, 22 ft.*lbf }

  29. INSTALL TUBE CONNECTOR TO FLEXIBLE HOSE TUBE (for 1VD-FTV)


    1. A0159ZG

      Temporarily install the flare nut of the tube connector to flexible hose tube to the clutch tube to release cylinder 2 way by hand.

    2. A0155T9E01

      Temporarily install the tube connector to flexible hose tube with the 2 bolts.

    3. Tighten the bolt labeled A.

      Torque:
      20 N*m  { 204 kgf*cm, 15 ft.*lbf }

      Note

      Tighten the bolt labeled B after installing the clutch hose.

  30. INSTALL AIR TUBE SUB-ASSEMBLY LH (for 1VD-FTV)

    A0156B9E01

    1. Install the air tube to the throttle body.

    2. Align the embossed mark of the throttle body with the paint mark of the No. 4 air hose.

    3. A0159R6E03

      Tighten the hose clamp so that it is 7 to 11 mm (0.276 to 0.433 in.) from the end of the hose as shown in the illustration.

      Torque:
      6.3 N*m  { 64 kgf*cm, 56 in.*lbf }

  31. INSTALL CLUTCH HOSE (for 1VD-FTV)


    1. A015BLRE01

      Connect the clutch hose to the air tube with the bolt labeled A.

    2. Temporarily install the clutch hose to the clutch master cylinder tube to flexible hose tube and tube connector to flexible hose tube, and fix it in place with the 2 clips.

      Torque:
      20 N*m  { 204 kgf*cm, 15 ft.*lbf }

    3. Tighten the bolt labeled B.

      Torque:
      20 N*m  { 204 kgf*cm, 15 ft.*lbf }

    4. Tighten the flexible hose tube.

      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 points.

      Tech Tips


      • Use a torque wrench with a fulcrum length of 30 cm (11.8 in.). If using a torque wrench with a length that is not 30 cm (11.8 in.), calculate the torque specification for the torque wrench and SST based on the "without SST" torque specification Click here.

      • Make sure union nut wrench and the wrench are connected in a straight line.


      1. A0155EJE01

        Using a 10 mm union nut wrench, tighten the 2 flare nuts of the flexible hose tube.

        Torque:
        without union nut wrench
        15 N*m  { 154 kgf*cm, 11 ft.*lbf }
        with union nut wrench
        14 N*m  { 141 kgf*cm, 10 ft.*lbf }
      2. A015C6PE01

        Using a 10 mm union nut wrench, tighten the flare nut of the flexible hose tube.

        Torque:
        without union nut wrench
        15 N*m  { 154 kgf*cm, 11 ft.*lbf }
        with union nut wrench
        14 N*m  { 141 kgf*cm, 10 ft.*lbf }

  32. INSTALL NO. 2 COOL AIR INLET (w/o Intercooler)


    1. A015AQ2E02
      Text in Illustration
      *1 Protrusion
      *a Front
      *b LH Side

      Install a new gasket to the air tube LH.

      Tech Tips

      Install the gasket with the protrusion facing as shown in the illustration.

    2. Install the No. 2 cool air inlet with the 3 nuts and bolt.

      Torque:
      21 N*m  { 214 kgf*cm, 15 ft.*lbf }
    3. A015BUCE02
      Text in Illustration
      *1 Protrusion
      *2 Paint Mark
      *a Top

      Connect the No. 2 air hose to the No. 2 cool air inlet.

    4. Tighten the No. 2 air hose clamp.

      Torque:
      6.3 N*m  { 64 kgf*cm, 56 in.*lbf }

      Tech Tips


      • Align the paint mark of the air hose with the protrusion and push on the air hose so that distance B is 0 to 3 mm (0 to 0.118 in.).

      • Position the clamp so that distance A is 2 to 6 mm (0.0787 to 0.236 in.).

      • Make sure the direction of the hose clamp is as shown in the illustration.

  33. INSTALL INTERCOOLER ASSEMBLY (w/ Intercooler)


    1. Click here

  34. INSTALL NO. 1 ENGINE COVER SUB-ASSEMBLY


    1. A015BEI

      Install the engine cover with the 2 nuts.

      Torque:
      8.0 N*m  { 82 kgf*cm, 71 in.*lbf }

  35. INSTALL FLOOR SHIFT LEVER ASSEMBLY


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

    2. Cover the shift lever cap with a cloth.

    3. Press down on the shift lever cap and rotate it clockwise to install it.

  36. INSTALL SHIFT LEVER BOOT ASSEMBLY

    A0157IJ

    1. Install the shift lever retainer and shift lever boot with the 4 screws.

  37. INSTALL UPPER CONSOLE PANEL SUB-ASSEMBLY

    w/o Console Box Lid Click here

    w/ Cool Box Click here

    w/o Cool Box Click here

  38. FILL RESERVOIR WITH BRAKE FLUID


    1. Fill the reservoir with brake fluid.

      Brake Fluid
      SAE J1703 or FMVSS No. 116 DOT 3

  39. BLEED CLUTCH LINE

    A015C3Z

    1. Remove the release cylinder bleeder plug cap.

    2. Connect a vinyl tube to the bleeder plug.

    3. Depress the clutch pedal several times, and then loosen the bleeder plug while the pedal is depressed.

    4. When fluid no longer comes out, tighten the bleeder plug, and then release the clutch pedal.

    5. Repeat the previous 2 steps until all the air in the fluid is completely bled.

    6. Tighten the bleeder plug.

      Torque:
      11 N*m  { 110 kgf*cm, 8 ft.*lbf }

    7. Install the bleeder plug cap.

    8. Check that all the air has been bled from the clutch line.

  40. CHECK FLUID LEVEL IN RESERVOIR


    1. Check the fluid level.

      If the brake fluid level is low, check for leaks and inspect the disc brake pad. If necessary, refill the reservoir with brake fluid after repair or replacement.

      Brake fluid
      SAE J1703 or FMVSS No. 116 DOT 3

  41. INSPECT FOR CLUTCH FLUID LEAK

  42. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

    Note

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