MANUAL TRANSMISSION ASSEMBLY REMOVAL

DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL

REMOVE CONSOLE BOX ASSEMBLY

Click here

REMOVE SHIFT LEVER BOOT ASSEMBLY

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.

REMOVE 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 counterclockwise to remove it.

3. Pull out the shift lever.

REMOVE TRANSFER HIGH AND LOW SHIFT LEVER ASSEMBLY

1. Using needle nose pliers, remove the snap ring and pull out the shift lever.

   Tech Tips

   Move the transfer shift lever to the H4 position.

REMOVE TRANSFER CASE LOWER PROTECTOR

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

REMOVE NO. 1 ENGINE UNDER COVER

REMOVE NO. 2 ENGINE UNDER COVER

REMOVE NO. 3 ENGINE UNDER COVER

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 }

REMOVE REAR PROPELLER SHAFT ASSEMBLY

for TSAM Made: Click here

for TMT Made: Click here

REMOVE FRONT PROPELLER SHAFT ASSEMBLY

for TSAM Made: Click here

for TMT Made: Click here

REMOVE FRONT EXHAUST PIPE ASSEMBLY

for 2TR-FE: Click here

for 1GR-FE: Click here

for 1KD-FTV: Click here

for 1KD-FTV for DPF: Click here

for 2KD-FTV: Click here

for 2KD-FTV for DPF: Click here

DISCONNECT WIRE HARNESS

1. Transmission side:

   Disconnect the back-up light switch connector.

2. Transfer side:

   Disconnect the No. 1, No. 2 and No. 3 transfer indicator switch connectors, and vehicle speed sensor connector.

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

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

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

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

2. 

   Using a union nut wrench, remove the flexible tube.

   Tech Tips

   Use a container to catch the fluid.

3. 

   Disconnect the clutch release cylinder to flexible hose tube.

4. Remove the bolt and 2 way.

5. 

   Remove the 2 bolts and the release cylinder.

6. 

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

REMOVE STARTER ASSEMBLY

for 2TR-FE 1.4 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 1KD-FTV 2.7 kW Type: Click here

for 2KD-FTV 2.0 kW Type: Click here

for 2KD-FTV 2.2 kW Type: Click here

for 2KD-FTV 2.7 kW Type: Click here

REMOVE NO. 3 FRAME CROSSMEMBER SUB-ASSEMBLY

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.

REMOVE REAR NO. 1 ENGINE MOUNTING INSULATOR

1. Remove the 4 bolts and engine mounting insulator.

REMOVE EXHAUST MANIFOLD STAY (for 2TR-FE)

1. Remove the 3 bolts and exhaust manifold stay.

REMOVE STIFFENER PLATE (for 1KD-FTV, 2KD-FTV)

1. Remove the 4 bolts and stiffener plate RH.

2. Remove the 4 bolts and stiffener plate LH.

REMOVE MANUAL TRANSMISSION UNIT ASSEMBLY

1. Using a transmission jack, support the transmission.

2. Remove the support stand from the rear side.

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

REMOVE TRANSFER ASSEMBLY

Click here