MANUAL TRANSMISSION ASSEMBLY REMOVAL


  1. REMOVE CABLE FROM NEGATIVE BATTERY TERMINAL

    CAUTION:

    Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag and seat belt pretensioner activation.

  2. REMOVE CONSOLE BOX ASSEMBLY

    Click here

  3. REMOVE SHIFT LEVER BOOT ASSEMBLY

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    1. w/o Console Box:

      Remove the front seat, front door scuff plate, etc. and fold back the floor carpet so that the shift lever can be removed.

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

  4. REMOVE FLOOR SHIFT SHIFT LEVER ASSEMBLY

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    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.

  5. REMOVE NO. 1 ENGINE UNDER COVER

  6. REMOVE NO. 2 ENGINE UNDER COVER

  7. DRAIN MANUAL TRANSMISSION OIL


    1. Remove the drain plug and gasket to drain the oil.

    2. Install a new gasket and the drain plug.

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

  8. REMOVE NO. 2 FRAME CROSSMEMBER ASSEMBLY

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    1. Remove the 4 bolts, 4 nuts and frame crossmember.

  9. REMOVE REAR PROPELLER SHAFT ASSEMBLY

    for TSAM Made: Click here

    for TMT Made: Click here

  10. REMOVE FRONT EXHAUST PIPE ASSEMBLY

    for 2TR-FE: Click here

    for 1GR-FE: Click here

    for 1KD-FTV: Click here

    for 2KD-FTV: Click here

    for 2KD-FTV for DPF: Click here

  11. DISCONNECT WIRE HARNESS


    1. Disconnect the back-up light switch connector and speedometer sensor connector.

  12. DISCONNECT CLUTCH RELEASE CYLINDER ASSEMBLY (for 1KD-FTV, 2TR-FE)

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

  13. REMOVE CLUTCH RELEASE CYLINDER ASSEMBLY (for 1GR-FE)

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    1. Remove the bolts, nut and release cylinder heat insulator.

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      Using a union nut wrench, remove the flexible tube.

      Tech Tips

      Use a container to catch the fluid.

    3. A01E025

      Disconnect the clutch release cylinder to flexible hose tube.

    4. Remove the bolt and 2 way.

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      Remove the 2 bolts and release cylinder.

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      Using a union nut wrench, disconnect the 2 flexible hose tubes.

  14. REMOVE STARTER ASSEMBLY

    for 2TR-FE 1.4 kW Type: Click here

    for 2TR-FE 1.6 kW Type: Click here

    for 2TR-FE 1.7 kW Type: Click here

    for 1GR-FE: Click here

    for 1KD-FTV 2.2 kW Type Bosch Made: Click here

    for 1KD-FTV 2.2 kW Type Denso Made: Click here

    for 2KD-FTV 2.2 kW Type: Click here

    for 2KD-FTV 2.7 kW Type: Click here

  15. REMOVE NO. 3 FRAME CROSSMEMBER SUB-ASSEMBLY

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

    2. Remove the 4 set bolts of the No. 1 engine mounting insulator rear.

    3. Remove the 4 bolts, 4 nuts and frame crossmember.

  16. REMOVE REAR NO. 1 ENGINE MOUNTING INSULATOR

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    1. Remove the 4 bolts and mounting insulator.

  17. REMOVE EXHAUST MANIFOLD STAY (for 2TR-FE)

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    1. Remove the 3 bolts and exhaust manifold stay.

  18. REMOVE STIFFENER PLATE (for 1KD-FTV)

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    1. Remove the 4 bolts and stiffener plate RH.

    2. Remove the 4 bolts and stiffener plate LH.

  19. REMOVE MANUAL TRANSMISSION UNIT ASSEMBLY

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    1. Using a transmission jack, support the transmission.

    2. Remove the support stand from the rear side.

    3. for 1KD-FTV:

      Remove the 5 bolts and transmission.

    4. for 2TR-FE:

      Remove the 7 bolts and transmission.

    5. for 1GR-FE:

      Remove the 9 bolts and transmission.