Manual Transmission Assembly -- Installation |
| 1. INSTALL MANUAL TRANSMISSION UNIT ASSEMBLY |
Make sure that the knock pins are not loose, bent, damaged or scratched.
Align the input shaft with the clutch disc and install the transmission to the engine.
for TR Engine series:
Install the 7 bolts.Text in Illustration *A for TR Engine series *b for 1KD-FTV, 2KD-FTV - Torque:
- for bolt A:
- 72 N*m{729 kgf*cm, 53 ft.*lbf}
- for bolt B:
- 37 N*m{379 kgf*cm, 27 ft.*lbf}
 |
for 1KD-FTV, 2KD-FTV:
Install the 5 bolts.- Torque:
- 72 N*m{729 kgf*cm, 53 ft.*lbf}
| 2. INSTALL STIFFENER PLATE (for 1KD-FTV, 2KD-FTV) |
Install the stiffener plate RH with the 4 bolts.
- Torque:
- 72 N*m{729 kgf*cm, 53 ft.*lbf}
Install the stiffener plate LH with the 4 bolts.
- Torque:
- 72 N*m{729 kgf*cm, 53 ft.*lbf}
| 3. INSTALL MANIFOLD STAY (for TR Series Engine) |
for Manual Transmission:
Install the manifold stay with the 3 bolts.- Torque:
- for bolt A:
- 72 N*m{729 kgf*cm, 53 ft.*lbf}
- for bolt B:
- 44 N*m{449 kgf*cm, 32 ft.*lbf}
- for bolt C:
- 30 N*m{306 kgf*cm, 22 ft.*lbf}
Text in Illustration 
Bolt A 
Bolt B 
Bolt C
 |
for Automatic Transmission:
Install the manifold stay with the 3 bolts.- Torque:
- for bolt A:
- 71 N*m{724 kgf*cm, 52 ft.*lbf}
- for bolt B:
- 44 N*m{449 kgf*cm, 32 ft.*lbf}
- for bolt C:
- 30 N*m{306 kgf*cm, 22 ft.*lbf}
Text in Illustration Bolt A Bolt B Bolt C
|
| 4. INSTALL REAR NO. 1 ENGINE MOUNTING INSULATOR |
Install the mounting insulator with the 4 bolts.
- Torque:
- 47 N*m{479 kgf*cm, 35 ft.*lbf}
| 5. INSTALL NO. 3 FRAME CROSSMEMBER SUB-ASSEMBLY |
Install the No. 3 frame crossmember sub-assembly with the 4 bolts and 4 nuts.
- Torque:
- 50 N*m{510 kgf*cm, 37 ft.*lbf}
Connect the No. 3 frame crossmember sub-assembly to the No. 1 rear engine mounting insulator.
- Torque:
- 27 N*m{275 kgf*cm, 20 ft.*lbf}
| 6. INSTALL STARTER ASSEMBLY |
for 2TR-FBE: (HILUX_TGN26 RM000000SGZ01DX.html)
for 1KD-FTV: (HILUX_TGN26 RM0000013XI04BX.html)
for 2KD-FTV DENSO made: (HILUX_TGN26 RM0000013XI04CX.html)
for 2KD-FTV BOSCH made: (HILUX_TGN26 RM0000013XI04DX.html)
| 7. CONNECT CLUTCH RELEASE CYLINDER ASSEMBLY |
Install the clutch release cylinder with the 2 bolts.
- Torque:
- 12 N*m{119 kgf*cm, 9 ft.*lbf}
| 8. CONNECT WIRE HARNESS |
Connect the back-up light switch connector and speedometer sensor connector.
| 9. INSTALL FRONT EXHAUST PIPE ASSEMBLY |
for 2TR-FBE: (HILUX_TGN26 RM00000135701IX.html)
for 1KD-FTV: (HILUX_TGN26 RM00000121201DX.html)
for 2KD-FTV w/o DPF: (HILUX_TGN26 RM00000121201EX.html)
for 2KD-FTV w/ DPF: (HILUX_TGN26 RM00000456800DX.html)
| 10. INSTALL PROPELLER WITH CENTER BEARING SHAFT ASSEMBLY |
| 11. ADD MANUAL TRANSMISSION OIL |
Add manual transmission oil until the oil level is within 5 mm (0.196 in.) from the bottom of the filler plug opening.
Text in Illustration *a 0 to 5 mm (0 to 0.196 in.) - Oil grade:
- GL-4 or GL-5
- Viscosity:
- SAE 75W-90, 80 or 80W-90
- Standard capacity:
- 2.6 liters (2.7 US qts, 2.3 Imp. qts)
 |
Install a new gasket and the filler plug.
- Torque:
- 37 N*m{377 kgf*cm, 27 ft.*lbf}
| 12. INSTALL FLOOR SHIFT LEVER ASSEMBLY |
Cover the shift lever cap with a cloth.
Press down on the shift lever cap and rotate it clockwise to install the floor shift lever assembly.
- HINT:
- Apply MP grease to the tip of the shift lever.
| 13. INSTALL SHIFT LEVER BOOT ASSEMBLY |
Install the shift lever boot with the 4 screws and 2 clips.
w/o Console Box:
Install the floor carpet, front seat, front door scuff plate, etc.
| 14. INSTALL CONSOLE BOX ASSEMBLY (w/ Console Box) |
| 15. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL |
- NOTICE:
- When disconnecting the cable, some systems need to be initialized after the cable is reconnected (HILUX_TGN26 RM000004QR300CX.html).