Install the 5th gear thrust washer lock ball, 5th gear thrust washer and 5th gear to the counter gear.

Using a dial indicator, measure the 5th gear radial clearance.

• Standard clearance:
• 0.008 to 0.034 mm (0.000315 to 0.00133 in.)

Using a dial indicator, measure the radial clearance.

• Standard clearance:
• 0.04 to 0.08 mm (0.00158 to 0.00314 in.)
• Maximum clearance:
• 0.08 mm (0.00314 in.)

Using a feeler gauge, measure the clearance between the reverse idler gear and reverse shift arm.

• Standard clearance:
• 0.05 to 0.35 mm (0.00197 to 0.0137 in.)
• Maximum clearance:
• 0.35 mm (0.0137 in.)

Apply gear oil to the cone part of the No. 5 gear spline piece, and check that the No. 1 synchronizer ring does not turn in either direction while pushing it against the No. 5 gear spline piece. If the No. 1 synchronizer ring turns, replace it.

Push the No. 1 synchronizer ring outer against the cone part of the No. 5 gear spline piece. Measure the clearance between the No. 1 synchronizer ring outer and No. 5 gear spline piece.

• Standard clearance:
• 0.85 to 1.55 mm (0.0335 to 0.0610 in.)

Check the sliding condition between the counter shaft 5th gear and No. 3 transmission hub sleeve.

Check the spline of the No. 3 transmission hub sleeve for wear.

Using a vernier caliper, measure the No. 3 transmission hub sleeve groove and the thickness of the claw part of the No. 3 shift fork and calculate the clearance.

• Standard clearance:
• 0.25 to 0.45 mm (0.00985 to 0.0177 in.)

Using a cylinder gauge, measure the inside diameter of the counter 5th gear.

• Standard inside diameter:
• 33.015 to 33.040 mm (1.2990 to 1.3007 in.)
• Maximum inside diameter:
• 33.040 mm (1.3007 in.)

Remove the filler plug and gasket from the manual transmission case.

Remove the drain plug and gasket from the manual transmission case.

Remove the release fork and release bearing from the clutch housing.

Remove the clip and release bearing from the release fork.

Remove the release fork support from the front transmission case.

Remove the clutch release fork boot from the front transmission case.

Using SST, remove the back-up light switch and gasket from the manual transmission case.

• SST
• 09817-16011

Remove the 9 bolts.

Using a plastic-faced hammer, tap off the front transmission case from the manual transmission case.

Remove the 2 restrict pins from the transfer adapter.

Remove the 4 bolts from the transfer adapter.

Remove the gasket from the adapter.

Using a T40 "TORX" socket, remove the spring seat from the transfer adapter.

Using a magnet hand, remove the compression spring and shift detent ball from the transfer adapter.

Remove the bolt from the shift lever housing.

Remove the 8 bolts.

Using a plastic-faced hammer, tap off the transfer adapter from the manual transmission case.

Remove the magnet from the transfer adapter.

Remove the receiver pipe from the transfer adapter.

Remove the shift and select lever and shift lever housing from the transfer adapter.

Using a T40 "TORX" socket, remove the plug from the transfer adapter.

Using a 5 mm pin punch and hammer, tap out the restrict slotted spring pin from the transfer adapter.

Remove the restrict pin from the transfer adapter.

Using a screwdriver and hammer, tap out the oil seal from the transfer adapter.

• ПРИМЕЧАНИЕ:

• Be careful no to damage the surface which contacts the oil seal.

Remove the 8 bolts.

Remove the bearing retainer and gasket from the transmission case.

Using a screwdriver, pry out the oil seal from the front bearing retainer.

• ПРИМЕЧАНИЕ:

• Be careful no to damage the surface which contacts the oil seal.

Using a snap ring expander, remove the snap ring from the input shaft front bearing.

Using a snap ring expander, remove the snap ring from the counter gear front bearing.

Stand the transmission as shown in the illustration.

Using a plastic-faced hammer, carefully tap off the transmission case as shown in the illustration.

Remove the transmission case from the intermediate plate.

Fix the intermediate plate in a vise between aluminum plates.

Using a T40 "TORX" socket, remove the spring seat and 2 ball plugs from the intermediate plate.

Using a magnet hand, remove the 3 compression springs and 3 shift detent balls from the intermediate plate.

Using a T40 "TORX" socket, remove the spring seat from the intermediate plate.

Using a magnet hand, remove the compression spring and No. 2 detent ball from the intermediate plate.

Remove the bolt from the No. 3 gear shift fork.

Remove the shift detent ball from the reverse shift head.

Remove the No. 4 gear shift fork shaft, shift detent ball and No. 3 gear shift fork from the intermediate plate.

Using a 5 mm pin punch and a hammer, tap out the slotted spring pin from the reverse shift head

Remove the reverse shift head and No. 5 gear shift fork shaft from the intermediate plate.

Using a magnet hand, remove the No. 2 shift interlock pin from the No. 3 gear shift fork shaft.

Using 2 screwdrivers and a hammer, remove the reverse shift head ring from the No. 3 shift fork shaft.

Using a 5 mm pin punch and a hammer, tap out the slotted spring pin from the No. 3 shift fork shaft.

Remove the No. 3 shift fork shaft from the intermediate plate.

Remove the reverse shift arm from the reverse shift arm bracket.

Using a screwdriver, remove the reverse shift arm E-ring.

Remove the reverse shift fork from the reverse shift arm.

Using a screwdriver, remove the shift arm shoe E-ring.

Remove the shift arm shoe from the reverse shift arm.

Using a magnet hand, remove the No. 3 shift interlock pin from the intermediate.

Using a magnet hand, remove the No. 2 shift interlock pin from the No. 1 gear shift fork shaft.

Using 2 screwdrivers and a hammer, remove the shaft snap ring from the No. 1 gearshift fork shaft.

Remove the bolt from the No. 1 gear shift fork.

Remove the No. 1 gear shift fork shaft from the intermediate plate.

Using a magnet hand, remove the shift interlock pin from the intermediate plate.

Remove the bolt from the No. 2 gear shift fork.

Using 2 screwdrivers and a hammer, remove the shaft snap ring from the No. 2 gear shift fork shaft.

Remove the No. 2 gear shift fork shaft, No. 1 gear shift fork and No. 2 gear shift fork from the intermediate plate.

Using a feeler gauge, measure the counter shaft 5th gear thrust clearance.

• Standard clearance:
• 0.10 to 0.30 mm (0.00394 to 0.0118 in.)

Using 2 screwdrivers and a hammer, tap out the counter gear rear shaft snap ring from the counter gear.

Using SST, remove the No. 5 gear spline and the No. 1 synchronizer ring from the counter gear.

• SST
• 09950-50013(09951-05010,09952-05010,09953-05010,09954-05021)

Remove the counter shaft 5th gear and the counter 5th gear bearing from the counter gear.

Remove the No. 3 transmission hub sleeve, 2 synchromesh shifting key springs, 3 synchromesh shifting keys, counter 5th gear bearing and counter shaft 5th gear.

Remove the 5th gear thrust washer from the counter gear.

Using a magnet hand, remove the 5th gear bearing inner race lock ball from the counter gear.

Remove the 2 bolts and reverse shift arm bracket from the intermediate plate.

Remove the bolt and reverse idler gear shaft stopper from the intermediate plate.

Remove the reverse idler gear shaft and the reverse idler gear from the intermediate plate.

Using a dial indicator, measure the reverse idler gear radial clearance.

• Standard clearance:
• 0.04 to 0.08 mm (0.00158 to 0.00314 in.)

• Maximum clearance:
• 0.08 mm (0.00314 in.)

Using a feeler gauge, measure the clearance between the reverse idler gear and the shift arm shoe.

• Standard clearance:
• 0.05 to 0.28 mm (0.00197 to 0.0110 in.)

• Maximum clearance:
• 0.28 mm (0.00110 in.)

Using a T40 "TORX" socket wrench, remove the 4 screws and output shaft rear bearing retainer from the intermediate plate.

Using a snap ring expander, remove the counter shaft center bearing snap ring from the counter shaft center bearing.

Using SST, remove the counter shaft center bearing and counter gear from the intermediate plate.

• SST
• 09950-40011(09951-04010,09952-04010,09953-04010,09954-04010,09955-04011,09958-04011)

Remove the input shaft with the 13 input shaft bearings and No. 2 synchronizer ring from the output shaft.

Using a snap ring expander, remove the output shaft bearing shaft snap ring from the output shaft bearing.

Remove the output shaft from the intermediate plate by pulling on the output shaft and tapping on the intermediate plate with a plastic-faced hammer.

Для моделей с 1KD-FTV:

Закрепите раздаточную коробку в сборе с помощью 8 болтов и 2 кронштейнов.

• Момент затяжки:
• 24 N*m{ 245 kgf*cm, 18 ft.*lbf}

• ПРИМЕЧАНИЕ:

• Соблюдайте осторожность, чтобы не повредить задний сальник переходника шлицами первичной шестерни раздаточной коробки.

Кроме моделей с 1KD-FTV:

Закрепите раздаточную коробку в сборе с помощью 8 болтов и кронштейна.

• Момент затяжки:
• 24 N*m{ 245 kgf*cm, 18 ft.*lbf}

• ПРИМЕЧАНИЕ:

• Соблюдайте осторожность, чтобы не повредить задний сальник переходника шлицами первичной шестерни раздаточной коробки.

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

Install the 4 bolts.

• Момент затяжки:
• 72 N*m{ 730 kgf*cm, 52 ft.*lbf}

Install the stiffener plate with the 4 bolts.

• Момент затяжки:
• for bolt A:
• 37 N*m{ 380 kgf*cm, 27 ft.*lbf}
• for bolt B:
• 69 N*m{ 701 kgf*cm, 50 ft.*lbf}

Install the stiffener plate with the 4 bolts.

• Момент затяжки:
• for bolt A:
• 37 N*m{ 380 kgf*cm, 27 ft.*lbf}
• for bolt B:
• 69 N*m{ 701 kgf*cm, 50 ft.*lbf}

Install the mounting insulator with the 4 bolts.

• Момент затяжки:
• 65 N*m{ 663 kgf*cm, 48 ft.*lbf}

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

• Момент затяжки:
• 72 N*m{ 734 kgf*cm, 53 ft.*lbf}

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

• Момент затяжки:
• 30 N*m{ 306 kgf*cm, 22 ft.*lbf}

Install the member bracket with the 4 bolts.

• Момент затяжки:
• 33 N*m{ 337 kgf*cm, 24 ft.*lbf}

Install the member bracket with the 4 bolts.

• Момент затяжки:
• 33 N*m{ 337 kgf*cm, 24 ft.*lbf}

Install the starter (See page ).

Connect the release cylinder with the 2 bolts.

• Момент затяжки:
• 12 N*m{ 120 kgf*cm, 9 ft.*lbf}

Install the 3 breather hoses to the shift lever retainer and transfer adapter and attach the clamp.

Connect the 2 connectors and attach the 4 clamps.

Install the front exhaust pipe (See page ).

Install the propeller shaft (See page ).

Install the front propeller shaft (See page ).

Install the transfer case lower protector with the 4 bolts.

• Момент затяжки:
• 18 N*m{ 184 kgf*cm, 13 ft.*lbf}

Cover the shift lever cap with a cloth.

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

• УКАЗАНИЕ:

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

Install the boot with the 4 screws and 2 clips.

Подсоедините все разъемы.

Введите в зацепление 8 фиксаторов и 2 захвата и установите облицовку панели пола.

Наклейте защитную клейкую ленту вокруг облицовки панели пола.

С помощью съемника молдингов расцепите 8 фиксаторов и 2 захвата.

Отсоедините все разъемы и снимите облицовку панели пола.

Remove the 4 screws, 2 clips and boot.

Cover the shift lever cap with a cloth.

Press down on the shift lever cap and rotate it counterclockwise to remove it.

Pull out the shift lever to remove it.

Remove the 4 bolts and transfer case lower protector.

Remove the drain plug and gasket and then drain the manual transmission oil.

Remove the filler plug and gasket.

Install a new gasket and the drain plug.

• Момент затяжки:
• 37 N*m{ 377 kgf*cm, 27 ft.*lbf}

Remove the front propeller shaft (See page ).

Remove the propeller shaft (See page ).

Remove the front exhaust pipe (See page ).

Disconnect the 2 connectors and detach the 4 clamps.

Detach the clamp and disconnect the 3 breather hoses from the shift lever retainer and transfer adapter.

Remove the breather hose.

Remove the 2 bolts and disconnect the release cylinder.

Remove the starter (See page ).

Remove the 4 bolts and member bracket.

Remove the 4 bolts and member bracket.

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

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

Remove the 4 bolts, 4 nuts and frame crossmember.

Remove the 4 bolts and engine mounting insulator.

Remove the 4 bolts and stiffener plate.

Remove the 4 bolts and stiffener plate.

Using a transmission jack, support the transmission.

Remove the support stand from the transmission.

Remove the 4 bolts and transmission.

Для моделей с 1KD-FTV:

Выверните 8 болтов и снимите 2 кронштейна.

Кроме моделей с 1KD-FTV:

Выверните 8 болтов и снимите кронштейн.

Отсоедините раздаточную коробку от трансмиссии.

Using SST, install a new gasket and the back-up light switch to the transmission case.

• SST
• 09817-16011

• Момент затяжки:
• 37 N*m{ 377 kgf*cm, 27 ft.*lbf}

Измерьте сопротивление в соответствии со значениями, приведенными в таблице ниже.

• Номинальное сопротивление:

• Контакты для подключения диагностического прибора	Положение переключателя	Заданные условия
  1 - 2	Нажат	Менее 1 Ом
  1 - 2	Отпущен	10 кОм или более

Disconnect the connector.

Using SST, remove the back-up light switch and gasket from the transmission case.

• SST
• 09817-16011