MANUAL TRANSMISSION ASSEMBLY > INSTALLATION

for Preparation Click here

1. Install the transfer assembly (Click here).
   

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

2. 1KD-FTV, 2KD-FTV:
   Install the 5 bolts.
   

   Torque:

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

3. 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

4. 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

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

   Torque:

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

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

   Torque:

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

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

1. Install the mounting insulator with the 4 bolts.
   

   Torque:

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

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:

   27 N*m{ 275 kgf*cm , 20 ft.*lbf }

1. Install the starter assembly.
   For 1KD-FTV (Click here)
   For 2KD-FTV (Click here)
   For 2TR-FE (Click here)
   For 1GR-FE (Click here)
   

1. Install the release cylinder with the 2 bolts.
   

   Torque:

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

1. Install the accumulator with the 3 bolts.
   

   Torque:

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

2. Using SST, connect the 2 flexible hose tubes.
   

   SST

   09023-00100  
   

   Torque:

   15 N*m{ 153 kgf*cm , 11 ft.*lbf } for use without SST

   14 N*m{ 143 kgf*cm , 10 ft.*lbf } for use with SST

   HINT:

   Use a torque wrench with a fulcrum length of 30 cm (11.81 in.).

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

   Torque:

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

4. Using SST, connect the flexible tube.
   

   SST

   09023-00100  
   

   Torque:

   15 N*m{ 153 kgf*cm , 11 ft.*lbf } for use without SST

   14 N*m{ 143 kgf*cm , 10 ft.*lbf } for use with SST

   HINT:

   Use a torque wrench with a fulcrum length of 30 cm (11.81 in.).

5. Install the 2 way with the bolt.
   

   Torque:

   19 N*m{ 194 kgf*cm , 14 ft.*lbf }

6. Using SST, install the flexible tube.
   

   SST

   09023-00100  
   

   Torque:

   15 N*m{ 153 kgf*cm , 11 ft.*lbf } for use without SST

   14 N*m{ 143 kgf*cm , 10 ft.*lbf } for use with SST

   HINT:

   Use a torque wrench with a fulcrum length of 30 cm (11.81 in.).

7. Install the release cylinder heat insulator with the bolt and the nut.
   

   Torque:

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

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.
   

1. Install the front exhaust pipe assembly.
   For 1KD-FTV (Click here)
   For 2KD-FTV (Click here)
   For 2TR-FE (Click here)
   For 1GR-FE (Click here)
   

1. Install the rear propeller shaft assembly (Click here).
   

1. Install the front propeller shaft assembly (Click here).
   

Oil grade:

GL-4 or GL-5

Viscosity:

SAE 75W-90

Capacity:

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

Torque:

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

Torque:

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

Torque:

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

1. Install the transfer case lower protector with the 4 bolts.
   

   Torque:

   18 N*m{ 183 kgf*cm , 13 ft.*lbf }

1. Install the transfer shift lever.
   

2. Using pliers, install the snap ring.
   

   HINT:

   Apply MP grease to the tip of the transfer shift lever.

1. Cover the shift lever cap with a cloth.
   

2. Press down on the shift lever cap and rotate it clockwise to install it.
   

   HINT:

   Apply MP grease to the tip of the shift lever.

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

1. Install the console box with the 2 clips, 4 screws <F> and 2 bolts <E>.
   

NOTICE:

Be careful not to damage the instrument panel lower and console box with the claws of the console panel upper.

1. Attach the 12 claws to install the console panel.
   

1. w/ M/T:
   Twist the knob in the direction indicated by the arrow to install it.
   

2. w/ 4WD:
   Twist the transfer shift lever knob in the direction indicated by the arrow to install it.
   

1. Perform initialization (Click here).
   

   NOTICE:

   Certain systems need to be initialized after disconnecting and reconnecting the cable from the negative (-) battery terminal.

1. Check the SRS warning light (Click here).
   

1. Bleed air from the clutch system.
   

   Torque:

   11 N*m{ 112 kgf*cm , 8 ft.*lbf }

2. Fill the master cylinder reservoir with fluid.
   

1. Check for clutch fluid leakage (Click here).
   

1. Inspect and adjust clutch pedal assembly.
   For LHD (Click here)
   For RHD (Click here)
   

1. Check fluid level in reservoir (Click here).