MANUAL TRANSMISSION ASSEMBLY REMOVAL


  1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL

    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.

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

  2. REMOVE SHIFT LEVER KNOB SUB-ASSEMBLY


    1. Remove the knob from the shift lever.

  3. REMOVE CONSOLE PANEL SUB-ASSEMBLY

    A009AEUE01
    Text in Illustration
    *1 Protective Tape

    1. Put protective tape around the console panel.

    2. Using a moulding remover, detach the 8 clips and 2 claws.

    3. Disconnect each connector and remove the console panel.

  4. REMOVE NO. 1 SHIFT AND SELECT LEVER BOOT


    1. A00O3K7E01
      Text in Illustration
      *1 Clip
      *2 Screw

      Remove the 4 screws, 2 clips and shift and select lever boot.

  5. REMOVE FLOOR SHIFT SHIFT LEVER ASSEMBLY

    A00O4PCE13
    Text in Illustration
    *1 Cloth
    *a Down
    *b Counterclockwise

    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 to remove it.

  6. REMOVE TRANSFER CASE LOWER PROTECTOR


    1. Remove the 4 bolts and lower protector.

  7. DRAIN MANUAL TRANSMISSION OIL


    1. A0099AOE01

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

    2. A009926E01

      Remove the filler plug and gasket.

    3. Install a new gasket and the drain plug.

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

  8. REMOVE FRONT PROPELLER SHAFT ASSEMBLY


    1. Remove the front propeller shaft Click here.

  9. REMOVE PROPELLER SHAFT ASSEMBLY


    1. Remove the propeller shaft Click here.

  10. DISCONNECT CLUTCH RELEASE CYLINDER ASSEMBLY

    A00O5B0

    1. Remove the 2 bolts and disconnect the release cylinder assembly.

  11. REMOVE STARTER ASSEMBLY


    1. for 1.4 kW Type:

      Remove the starter Click here.

    2. for 2.0 kW Type:

      Remove the starter Click here.

  12. REMOVE FRONT SUSPENSION MEMBER BRACKET LH


    1. A00O6ZI

      Remove the 4 bolts and member bracket.

  13. REMOVE FRONT SUSPENSION MEMBER BRACKET RH


    1. A00O3L7

      Remove the 4 bolts and member bracket.

  14. REMOVE NO. 3 FRAME CROSSMEMBER SUB-ASSEMBLY


    1. Support the rear side of the transmission with a support stand.

    2. A00O744

      Remove the 4 bolts from the mounting insulator.

    3. A00OB81

      Remove the 4 bolts, 4 nuts and frame crossmember.

  15. REMOVE REAR NO. 1 ENGINE MOUNTING INSULATOR

    A00O9WX

    1. Remove the 5 bolts, front engine mounting insulator and mounting insulator.

  16. REMOVE MANIFOLD STAY

    A00XGZ2

    1. Remove the 3 bolts and manifold stay.

  17. DISCONNECT WIRE HARNESS


    1. Disconnect the 2 connectors and 4 clamps.

      A00O31R

  18. DISCONNECT TRANSFER AND MANUAL TRANSMISSION BREATHER HOSE SUB-ASSEMBLY


    1. A00O46K

      Disconnect the 3 breather hoses from the transfer adapter and transfer.

    2. Disconnect the 2 breather hoses from the bracket.

  19. REMOVE MANUAL TRANSMISSION UNIT ASSEMBLY


    1. A00O6ZJ

      Using a transmission jack, support the transmission.

    2. Remove the support stand from the transmission.

    3. Remove the 8 bolts and transmission unit.

  20. REMOVE TRANSFER ASSEMBLY


    1. A00L0TGE01
      Text in Illustration
      *A for 1KD-FTV, RA61F
      *B for 1KD-FTV, A750F

      for 1KD-FTV:

      Remove the 8 bolts and 2 brackets.

    2. A00KZK2

      except 1KD-FTV:

      Remove the 8 bolts and bracket.

    3. Remove the transfer from the transmission.