MANUAL TRANSMISSION ASSEMBLY INSTALLATION

INSTALL TRANSFER ASSEMBLY
1. Install the transfer Click here.
INSTALL MANUAL TRANSMISSION UNIT ASSEMBLY
1. Align the input shaft with the clutch disc and install the transmission to the engine.
2. 2TR-FE:
  
  Install the 7 bolts.
  
  Torque:
  
  72 N*m { 730 kgf*cm, 53 ft.*lbf, for bolt A }
  
  37 N*m { 377 kgf*cm, 27 ft.*lbf, for bolt B }
3. 1GR-FE:
  
  Install the 9 bolts.
  
  Torque:
  
  72 N*m { 730 kgf*cm, 53 ft.*lbf, for bolt A }
  
  37 N*m { 377 kgf*cm, 27 ft.*lbf, for bolt B }
INSTALL EXHAUST MANIFOLD STAY (for 2TR-FE)
1. Install the exhaust manifold stay with the 3 bolts.
  
  Torque:
  
  44 N*m { 449 kgf*cm, 32 ft.*lbf, for bolt A }
  
  30 N*m { 306 kgf*cm, 22 ft.*lbf, for bolt B }
  
  72 N*m { 730 kgf*cm, 53 ft.*lbf, for bolt C }
INSTALL REAR NO. 1 ENGINE MOUNTING INSULATOR
1. Install the mounting insulator with the 4 bolts.
  
  Torque:
  
  44 N*m { 449 kgf*cm, 32 ft.*lbf }
INSTALL NO. 3 FRAME CROSSMEMBER SUB-ASSEMBLY
1. Install the frame crossmember with the 4 bolts and 4 nuts.
  
  Torque:
  
  50 N*m { 510 kgf*cm, 37 ft.*lbf, for bolt A }
2. Install the 4 set bolts to the No. 1 engine mounting insulator rear.
  
  Torque:
  
  27 N*m { 275 kgf*cm, 20 ft.*lbf, for bolt B }
INSTALL STARTER ASSEMBLY

for 2TR-FE: Click here

for 1GR-FE: Click here
CONNECT CLUTCH RELEASE CYLINDER ASSEMBLY (for 2TR-FE)
1. Install the release cylinder with the 2 bolts.
  
  Torque:
  
  12 N*m { 120 kgf*cm, 9 ft.*lbf }
INSTALL CLUTCH RELEASE CYLINDER ASSEMBLY (for 1GR-FE)
1. Install the accumulator with the 3 bolts.
  
  Torque:
  
  12 N*m { 120 kgf*cm, 9 ft.*lbf }
2. Using union nut wrench connect the 2 flexible hose tubes.
  
  Torque:
  
  15.5 N*m { 158 kgf*cm, 11 ft.*lbf }
  
  Note
  
  Use the formula to calculate special torque value for situations where a union nut wrench is combined with a torque wrench Click here.
3. Install the clutch release cylinder with the 2 bolts.
  
  Torque:
  
  12 N*m { 120 kgf*cm, 9 ft.*lbf }
4. Using union nut wrench, connect the flexible tube.
  
  Torque:
  
  15.5 N*m { 158 kgf*cm, 11 ft.*lbf }
  
  Note
  
  Use the formula to calculate special torque value for situations where a union nut wrench is combined with a torque wrench Click here.
5. Install the 2 way with the bolt.
  
  Torque:
  
  19 N*m { 194 kgf*cm, 14 ft.*lbf }
6. Using union nut wrench, install the flexible tube.
  
  Torque:
  
  15.5 N*m { 158 kgf*cm, 11 ft.*lbf }
  
  Note
  
  Use the formula to calculate special torque value for situations where a union nut wrench is combined with a torque wrench Click here.
7. Install the release cylinder heat insulator with the bolt and the nut.
  
  Torque:
  
  12 N*m { 120 kgf*cm, 9 ft.*lbf }
CONNECT WIRE HARNESS
1. Transmission side:
  
  Connect the back-up light switch connector.
2. Transfer side:
  
  Connect the No. 1, No. 2 and No. 3 transfer indicator switch connectors, and vehicle speed sensor connector.
INSTALL FRONT EXHAUST PIPE ASSEMBLY

for 2TR-FE: Click here

for 1GR-FE: Click here
INSTALL REAR PROPELLER SHAFT ASSEMBLY

Click here
INSTALL FRONT PROPELLER SHAFT ASSEMBLY

Click here
ADD MANUAL TRANSMISSION OIL

Oil grade

GL-4 or GL-5

Viscosity

SAE 75W-90

Standard capacity

2.2 liters (2.3 US qts, 1.9 Imp. qts)

Torque:

37 N*m { 377 kgf*cm, 27 ft.*lbf }
INSTALL TRANSFER CASE LOWER PROTECTOR
1. Install the transfer case lower protector with the 4 bolts.
  
  Torque:
  
  18 N*m { 183 kgf*cm, 13 ft.*lbf }
INSTALL TRANSFER HIGH AND LOW SHIFT LEVER ASSEMBLY
1. Install the transfer shift lever.
  
  Tech Tips
  
  Apply MP grease to the tip of the transfer shift lever.
2. Using pliers, install the snap ring.
INSTALL FLOOR SHIFT SHIFT LEVER ASSEMBLY
1. Cover the shift lever cap with a cloth.
2. Press down on the shift lever cap and rotate it clockwise to install it.
  
  Tech Tips
  
  Apply MP grease to the tip of the shift lever.
INSTALL SHIFT LEVER BOOT ASSEMBLY
1. Install the shift lever boot with the 4 screws and 2 clips.
INSTALL CONSOLE BOX ASSEMBLY

Click here
CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
PERFORM INITIALIZATION
1. Perform initialization Click here.
  
  Note
  
  Certain systems need to be initialized after disconnecting and reconnecting the cable from the negative (-) battery terminal.
BLEED AIR FROM CLUTCH PIPE LINE (for 1GR-FE)
1. Remove the brake master cylinder reservoir filler cap assembly.
2. Add brake fluid to keep the level between the MIN and MAX lines of the reservoir while bleeding the clutch line.
  
  Fluid
  
  SAE J1703 or FMVSS No. 116 DOT3
3. Remove the bleeder plug cap.
4. Connect a vinyl tube to the bleeder plug.
5. Depress the clutch pedal several times, and then loosen the bleeder plug with the pedal depressed.
6. At the point when fluid stops coming out, tighten the bleeder plug, and then release the clutch pedal.
7. Repeat the previous 2 steps until all the air in the fluid is completely bled out.
8. Tighten the bleeder plug.
  
  Torque:
  
  11 N*m { 110 kgf*cm, 8 ft.*lbf }
9. Install the bleeder plug cap.
10. Check that all the air has been bled out of the clutch line.
11. Check for brake fluid leaks.
12. Check the brake fluid level in the reservoir Click here.
13. Install the brake master cylinder reservoir filler cap assembly.
CHECK FOR CLUTCH FLUID LEAKAGE
INSPECT AND ADJUST CLUTCH PEDAL ASSEMBLY (for 1GR-FE)

Click here
CHECK FLUID LEVEL IN RESERVOIR (for 1GR-FE)
1. Check the fluid level and add fluid if necessary.
  
  Fluid
  
  SAE J1703 or FMVSS No. 116 DOT3
  
  Tech Tips
  
  Add fluid to a level between the reservoir's MIN and MAX lines.
INSTALL NO. 3 ENGINE UNDER COVER

Torque:

28 N*m { 286 kgf*cm, 21 ft.*lbf }
INSTALL NO. 2 ENGINE UNDER COVER

Torque:

28 N*m { 286 kgf*cm, 21 ft.*lbf }
INSTALL NO. 1 ENGINE UNDER COVER

Torque:

28 N*m { 286 kgf*cm, 21 ft.*lbf }