MANUAL TRANSMISSION ASSEMBLY > INSTALLATION

for Preparation Click here



1. INSTALL MANUAL TRANSMISSION UNIT ASSEMBLY


C113299E05

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

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

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

  1. 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

  1. 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



2. INSTALL STIFFENER PLATE (1KD-FTV)


G034607E02

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

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

  1. 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)


B086194E02

  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


G034222E01

  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


B085193E02

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

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

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

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



6. INSTALL STARTER ASSEMBLY

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



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


G034217E02

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

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



8. CONNECT CLUTCH RELEASE CYLINDER ASSEMBLY (1GR-FE)


D030416E03

  1. Install the accumulator with the 3 bolts.

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

  1. 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



    C112662

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

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



    C112616

  1. 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

  1. Install the 2 way with the bolt.

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



    C112615

  1. 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.).



    C112617

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

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



9. CONNECT WIRE HARNESS

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



10. INSTALL FRONT EXHAUST PIPE ASSEMBLY

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



11. INSTALL REAR PROPELLER SHAFT ASSEMBLY

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



12. INSTALL NO. 2 FRAME CROSSMEMBER SUB-ASSEMBLY


D033401E02

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

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



13. ADD MANUAL TRANSMISSION OIL


D025304E06

Oil grade:
GL-4 or GL-5

Viscosity:
SAE 75W-90

Capacity:
2.6 liters (2.7 US qts, 2.3 lmp. qts)

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



14. INSTALL FLOOR SHIFT SHIFT LEVER ASSEMBLY

  1. Cover the shift lever cap with a cloth.

  1. 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.



15. INSTALL SHIFT LEVER BOOT ASSEMBLY


G034215E03

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



16. INSTALL CONSOLE BOX ASSEMBLY


B090153E01

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



17. INSTALL UPPER CONSOLE PANEL ASSEMBLY


B115418E02

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.



18. INSTALL SHIFT LEVER KNOB SUB-ASSEMBLY


B111105E01

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

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



19. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL


20. PERFORM INITIALIZATION

  1. Perform initialization (Click here).

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



21. CHECK SRS WARNING LIGHT

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



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

  1. Bleed air from the clutch system.

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

  1. Fill the master cylinder reservoir with fluid.



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

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



24. INSPECT AND ADJUST CLUTCH PEDAL ASSEMBLY (1GR-FE)

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



25. CHECK FOR FLUID LEVEL IN RESERVOIR (1GR-FE)

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