MANUAL TRANSMISSION ASSEMBLY REMOVAL

CAUTION / NOTICE / HINT

The necessary procedures (adjustment, calibration, initialization, or registration) that must be performed after parts are removed, installed, or replaced during the manual transmission assembly removal/installation are shown below.

Necessary Procedure After Parts Removed/Installed/Replaced
Replacement Part or Procedure Necessary Procedures Effects/Inoperative when not Performed Link

    for 1TR-FE:

  • Gas leak from exhaust system is repaired

 Inspection After Repair Poor idle, engine start, etc.

Click here


    for 2TR-FE:

  • Gas leak from exhaust system is repaired

 Inspection After Repair Poor idle, engine start, etc.

Click here

CAUTION:


  • B0068W8

    To prevent burns, do not touch the engine, exhaust pipe or other high temperature components while the engine is hot.

  • B00281GC03
    *a Object Exceeding Weight Limit of Transmission Jack

    The manual transmission assembly is very heavy. Be sure to follow the procedure described in the repair manual, or the transmission jack may suddenly drop or a part may fall.

PROCEDURE


  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 CONSOLE BOX ASSEMBLY (w/ Console Box Lid)

    Click here

  4. REMOVE FRONT CONSOLE BOX (w/o Console Box Lid)

    Click here

  5. REMOVE SHIFT LEVER BOOT ASSEMBLY


    1. B00245Z

      Remove the 6 screws, 4 clips and shift lever boot assembly.

  6. REMOVE FLOOR SHIFT SHIFT LEVER ASSEMBLY


    1. Remove the shift lever cover.

    2. B0027JE

      Detach the shift lever cap boot from the manual transmission.

    3. Cover the shift lever cap with a cloth.

    4. B0026ANC02
      *1 Shift Lever Cap
      *a Press Down
      *b Counterclockwise
      *c Pull out

      While pressing down on the shift lever cap, turn it counterclockwise, and then pull to remove the shift lever.

  7. REMOVE NO. 1 ENGINE UNDER COVER ASSEMBLY (for 2WD)

  8. REMOVE NO. 1 ENGINE UNDER COVER (for 2WD)

  9. REMOVE NO. 1 ENGINE UNDER COVER ASSEMBLY (for Pre-Runner)

  10. REMOVE NO. 2 ENGINE UNDER COVER (for Pre-Runner)

  11. REMOVE NO. 3 ENGINE UNDER COVER SUB-ASSEMBLY (for Pre-Runner)

  12. DRAIN MANUAL TRANSMISSION OIL


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

    2. Install a new gasket and the drain plug sub-assembly.

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

  13. REMOVE NO. 2 FRAME CROSSMEMBER SUB-ASSEMBLY (for 2WD)

    B00276T

    1. Remove the 4 bolts, 4 nuts and No. 2 frame crossmember sub-assembly.

  14. REMOVE PROPELLER SHAFT WITH CENTER BEARING ASSEMBLY

    Click here

  15. REMOVE FRONT EXHAUST PIPE ASSEMBLY


  16. DISCONNECT WIRE HARNESS


    1. B0025OF

      Disconnect the 2 clamps and connector.

    2. B0028B6

      Remove the bolt and disconnect the ground cable.

  17. DISCONNECT CLUTCH RELEASE CYLINDER ASSEMBLY

    Click here

  18. REMOVE STARTER ASSEMBLY (for 1GD-FTV)


  19. REMOVE STARTER ASSEMBLY (for 2GD-FTV)


  20. REMOVE STARTER ASSEMBLY (for 1TR-FE)


  21. REMOVE STARTER ASSEMBLY (for 2TR-FE)

    Click here

  22. REMOVE STARTER ASSEMBLY (for 2KD-FTV)


  23. SUPPORT MANUAL TRANSMISSION ASSEMBLY


    1. B0026Y8

      Support the manual transmission with a transmission jack.

      Note


      • Make sure the high transmission jack attachment is centered on the safety stand.

      • Secure the part with a rope, attachment, etc.

  24. REMOVE NO. 3 FRAME CROSSMEMBER SUB-ASSEMBLY


    1. B0026GQ

      Remove the 4 set bolts of the rear engine mounting insulator.

    2. B0024SA

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

  25. REMOVE REAR ENGINE MOUNTING INSULATOR


    1. B0024KK

      Remove the 4 bolts and rear engine mounting insulator.

  26. REMOVE MANIFOLD STAY (for 1TR-FE, 2TR-FE)


  27. REMOVE STIFFENER PLATE (except 1TR-FE, 2TR-FE)


    1. Remove the No. 4 cylinder block insulator.

    2. B0026I3

      for 1GD-FTV, 2GD-FTV:


      1. Remove the 4 bolts and stiffener plate RH and disconnect the wire harness.

      2. Remove the 4 bolts and stiffener plate LH.

    3. B002694

      for 2KD-FTV:


      1. Remove the 4 bolts and stiffener plate RH.

      2. Remove the 4 bolts and stiffener plate LH.

    4. Remove the No. 2 rear end plate.

  28. REMOVE MANUAL TRANSMISSION UNIT ASSEMBLY

    CAUTION:

    The manual transmission assembly is very heavy. Be sure to follow the procedure described in the repair manual, or the transmission jack may suddenly drop or a part may fall.


    1. B0026YOC01
      *A for 1TR-FE, 2TR-FE:
      *B except 1TR-FE, 2TR-FE:

      for 1TR-FE, 2TR-FE:

      Remove the 7 bolts, transmission breather bracket and manual transmission unit assembly.

    2. except 1TR-FE, 2TR-FE:

      Remove the 5 bolts, transmission breather bracket and manual transmission unit assembly.

    3. Operate the transmission jack and slowly remove the manual transmission unit assembly from the vehicle.

      Note

      Make sure that the manual transmission unit assembly is clear of all wiring and hoses.

  29. REMOVE TRANSMISSION BREATHER SUB-ASSEMBLY


    1. B0025CA

      Disconnect the 2 clamps and remove the transmission breather sub-assembly.

  30. REMOVE WIRE HARNESS CLAMP BRACKET


    1. B0025U2

      except 1TR-FE, 2TR-FE:

      Remove the 3 bolts and 3 wire harness clamp brackets from the manual transmission unit assembly.

    2. B0024H5

      for 1TR-FE, 2TR-FE:

      Remove the 2 bolts and 2 wire harness clamp brackets from the manual transmission unit assembly.