MANUAL TRANSMISSION ASSEMBLY INSTALLATION


  1. INSTALL MANUAL TRANSMISSION UNIT ASSEMBLY

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    1. Align the input shaft with the clutch disc and install the transmission to the engine.

    2. for 1KD-FTV, 2KD-FTV:

      Install the 5 bolts.

      Torque:
      72 N*m  { 730 kgf*cm, 53 ft.*lbf }

    3. for 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 }

  2. INSTALL STIFFENER PLATE (for 1KD-FTV)

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    1. Install the stiffener pate RH with the 4 bolts.

      Torque:
      72 N*m  { 730 kgf*cm, 53 ft.*lbf }

    2. Install the stiffener pate LH with the 4 bolts.

      Torque:
      72 N*m  { 730 kgf*cm, 53 ft.*lbf }

  3. INSTALL EXHAUST MANIFOLD STAY (for 2TR-FE)

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    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 }

  4. INSTALL REAR NO. 1 ENGINE MOUNTING INSULATOR

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    1. Install the mounting insulator with the 4 bolts.

      Torque:
      44 N*m  { 449 kgf*cm, 32 ft.*lbf }

  5. INSTALL NO. 3 FRAME CROSSMEMBER SUB-ASSEMBLY

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    1. Install the frame crossmember with the 4 bolts and 4 nuts.

      Torque:
      50 N*m  { 510 kgf*cm, 37 ft.*lbf }

    2. Install the 4 set bolts to the No. 1 engine mounting insulator rear.

      Torque:
      17 N*m  { 173 kgf*cm, 13 ft.*lbf }

  6. INSTALL 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 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

  7. CONNECT CLUTCH RELEASE CYLINDER ASSEMBLY

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    1. Install the clutch release cylinder with the 2 bolts.

      Torque:
      12 N*m  { 120 kgf*cm, 9 ft.*lbf }

  8. CONNECT WIRE HARNESS


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

  9. INSTALL FRONT EXHAUST PIPE ASSEMBLY

    for 2TR-FE: Click here

    for 1KD-FTV: Click here

    for 2KD-FTV: Click here

    for 2KD-FTV for DPF: Click here

  10. INSTALL REAR PROPELLER SHAFT ASSEMBLY

    for TSAM Made: Click here

    for TMT Made: Click here

  11. INSTALL NO. 2 FRAME CROSSMEMBER SUB-ASSEMBLY

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    1. Install the frame crossmember with the 4 bolts and 4 nuts.

      Torque:
      50 N*m  { 510 kgf*cm, 37 ft.*lbf }

  12. ADD MANUAL TRANSMISSION OIL

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    1. Stop the vehicle on a level surface.

    2. Remove the filer plug and gasket.

    3. Check that the oil level is between 0 to 5 mm (0 to 0.20 in.) from the bottom lip of the filler plug opening.

      If the result is not as specified, add transmission oil.

      Oil grade
      GL-4
      Viscosity
      SAE 75W-90, 80W or 80W-90
      Capacity
      2.6 liters (2.7 US qts, 2.3 Imp.qts)

      Note


      • Too much or too little oil will lead to transmission problems.

      • After adjusting the oil level, drive the vehicle and check the oil level again.

    4. Check for oil leakage when the oil level is low.

      If leakage is found, repair the area necessary to stop the leak. Replace damaged parts as necessary.

    5. Install a new gasket and the filler plug.

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

  13. INSTALL NO. 2 ENGINE UNDER COVER

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

  14. INSTALL NO. 1 ENGINE UNDER COVER

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

  15. 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.

  16. INSTALL SHIFT LEVER BOOT ASSEMBLY

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    1. Install the shift lever boot with the 4 screws and 2 clips.

    2. w/o Console Box:

      Install the floor carpet, front seat, front door scuff plate, etc.

  17. INSTALL CONSOLE BOX ASSEMBLY

    Click here

  18. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

  19. 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.

  20. CHECK SRS WARNING LIGHT

    Click here

  21. BLEED AIR FROM CLUTCH PIPE LINE (for 1GR-FE)

    Click here

  22. CHECK FOR CLUTCH FLUID LEAKAGE (for 1GR-FE)