MANUAL TRANSMISSION ASSEMBLY (for 1KD-FTV) 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

    A0094KM

    1. Remove the 7 screws.

    2. Detach the 4 claws and clip and remove the upper console panel.

  4. REMOVE SHIFT LEVER BOOT ASSEMBLY

    A00O3TL

    1. Remove the 4 screws and shift lever boot.

  5. REMOVE FLOOR SHIFT SHIFT LEVER ASSEMBLY

    A00O98W

    1. Detach the shift lever cap boot from the manual transmission.

    2. A00O3FXE01
      Text in Illustration
      *1 Cloth
      *a Down
      *b Counterclockwise

      Cover the shift lever cap with a cloth.

    3. While pressing down on the shift lever cap, turn it counterclockwise to remove the shift lever.

    4. Pull out the shift lever to remove it.

  6. DRAIN MANUAL TRANSMISSION OIL


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

    2. Install a new gasket and the drain plug.

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

  7. REMOVE FRONT EXHAUST PIPE ASSEMBLY

    w/o DPF: Click here

    w/ DPF: Click here

  8. REMOVE TRANSFER CASE LOWER PROTECTOR


    1. Remove the 4 bolts and transfer case lower protector.

  9. REMOVE FRONT PROPELLER SHAFT ASSEMBLY

    Click here

  10. REMOVE PROPELLER SHAFT ASSEMBLY

    Click here

  11. REMOVE STARTER ASSEMBLY

    for 2.2 kW Type: Click here

    for 2.7 kW Type: Click here

    for 3.0 kW Type: Click here

  12. DISCONNECT CLUTCH RELEASE CYLINDER ASSEMBLY


    1. A00O577

      Remove the 2 bolts and clip, and then disconnect the release cylinder.

  13. REMOVE FRONT SUSPENSION MEMBER BRACKET LH

    A00O4S9

    1. Remove the 4 bolts and front suspension member bracket LH.

  14. REMOVE FRONT SUSPENSION MEMBER BRACKET RH

    A00O8C2

    1. Remove the 4 bolts and front suspension member bracket RH.

  15. REMOVE NO. 3 FRAME CROSSMEMBER SUB-ASSEMBLY


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

    2. A00O5J8

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

    3. A00O38L

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

  16. REMOVE REAR NO. 1 ENGINE MOUNTING INSULATOR

    A00O5XK

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

  17. DISCONNECT WIRE HARNESS


    1. w/o DPF:


      1. A00O51L

        Detach the 5 wire harness clamps.

      2. Disconnect the 2 connectors and wire harness.

    2. w/ DPF:


      1. Disconnect the 3 connectors and 3 connector clamps.

        A00O6LPE01

      2. Detach the 8 wire harness clamps.

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


    1. w/o DPF:


      1. A00O39X

        Detach the breather hose clamp.

      2. Disconnect the 3 breather hoses.

    2. w/ DPF:


      1. A00OA9G

        Detach the 2 breather hose clamps.

      2. Disconnect the 3 breather hoses.

  19. REMOVE MANUAL TRANSMISSION WITH TRANSFER

    A00O5BH

    1. Remove the 8 bolts.

    2. Remove the manual transmission with transfer.

  20. REMOVE TRANSMISSION UPPER COVER SUB-ASSEMBLY

    A00OAS8

    1. Remove the 2 bolts and upper cover.

  21. REMOVE DIFFERENTIAL PRESSURE SENSOR ASSEMBLY (w/ DPF)


    1. A00O7TM

      Remove the nut and differential pressure sensor from the sensor bracket.

  22. 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.