Manual Transmission Assembly (For 1Gd-Ftv) Installation

Install the transfer assembly with the 8 bolts and bracket.

Torque:

24 N*m{245 kgf*cm, 18 ft.*lbf}

NOTICE:

Take care not to damage the adaptor rear oil seal with the transfer input gear spline.

Install the transmission upper cover sub-assembly with the 2 bolts.

Torque:

12 N*m{117 kgf*cm, 8 ft.*lbf}

w/o Urea SCR System:
Install the manual transmission with transfer with the 9 bolts.

Torque:

72 N*m{729 kgf*cm, 53 ft.*lbf}

w/ Urea SCR System:
Install the manual transmission with transfer with the 9 bolts and wire harness bracket.

Torque:

72 N*m{729 kgf*cm, 53 ft.*lbf}

Connect the 3 breather hoses.

Attach the breather hose clamp.

Attach the 5 wire harness clamps.

Connect the 2 connectors and wire harness.

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

Torque:

73 N*m{739 kgf*cm, 54 ft.*lbf}

Install the front engine mounting insulator RH with the bolt.

Torque:

12 N*m{122 kgf*cm, 9 ft.*lbf}

Install the No. 3 frame crossmember sub-assembly with the 4 bolts and 4 nuts.

Torque:

72 N*m{734 kgf*cm, 53 ft.*lbf}

Install the 4 bolts to the No. 3 frame crossmember sub-assembly.

Torque:

30 N*m{306 kgf*cm, 22 ft.*lbf}

Connect the urea tank sub-assembly with the bolt.

Torque:

14 N*m{146 kgf*cm, 11 ft.*lbf}

Install the front suspension member bracket LH with the 4 bolts.

Torque:

33 N*m{337 kgf*cm, 24 ft.*lbf}

Install the front suspension member bracket LH with the 4 bolts.

Torque:

33 N*m{337 kgf*cm, 24 ft.*lbf}

Install the front suspension member bracket RH with the 4 bolts.

Torque:

33 N*m{337 kgf*cm, 24 ft.*lbf}

for 2.0 kW Type:
Connect the starter assembly.

1. Connect the starter assembly with the 2 bolts.
   

   Torque:

   68 N*m{693 kgf*cm, 50 ft.*lbf}

2. Connect the starter wire with the nut.
   

   Torque:

   9.8 N*m{100 kgf*cm, 87 in.*lbf}

3. Connect the starter connector.
   

4. Close the terminal cap.
   

for 2.7 kW Type:
Connect the starter assembly.

1. Connect the starter assembly with the 2 bolts.
   

   Torque:

   68 N*m{693 kgf*cm, 50 ft.*lbf}





2. Connect the starter wire with the nut.
   

   Torque:

   21 N*m{215 kgf*cm, 16 ft.*lbf}

3. Connect the starter connector.
   

4. Close the terminal cap.
   

Install the front No. 1 fender apron to frame seal LH with the 5 clips.

Install the clutch flexible hose bracket with the 2 bolts.

Torque:

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

Temporarily install the clutch release cylinder to flexible hose tube with the 2 bolts, 3 nuts and a new clip.

Tighten the labeled A.

Torque:

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

Tighten the labeled B.

Torque:

15 N*m{155 kgf*cm, 11 ft.*lbf}

Install oil pan insulator with the 2 bolts.

Torque:

18 N*m{184 kgf*cm, 13 ft.*lbf}

Attach the 2 wire harness clamps and connect the wire harness.

Install the wire harness clamp bracket with the bolt.

Torque:

13 N*m{131 kgf*cm, 9 ft.*lbf}

Attach the 3 wire harness clamps and connect the wire harness.

Install the transfer case lower protector with the 4 bolts.

Torque:

18 N*m{184 kgf*cm, 13 ft.*lbf}

Park the vehicle on a level surface.

Check that the oil level is between 0 to 5 mm (0 to 0.196 in.) from the bottom lip of the filler plug opening.

1. If the result is not as specified, add transmission oil.
   

NOTICE:

1. Problems may occur when the oil level is too high or low.
   
2. After replacing the oil, drive the vehicle and check the oil level again.
   

Inspect for oil leaks when the oil level is low.

1. If the result is not as specified, add transmission oil.
   

Install a new gasket and the filler plug.

Torque:

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

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

Text in Illustration

MP Grease

Cover the shift lever cap with a cloth.

While pressing down on the shift lever cap, turn it clockwise to install the shift lever assembly.

Attach the shift lever cap boot.

Install the No. 1 shift and select lever boot with the 4 screws.

Fill the reservoir with brake fluid.

Brake fluid:

SAE J1703 or FMVSS No. 116 DOT 3

NOTICE:

for Hydraulic Brake Booster:

As brake fluid may overflow when fluid is released from the brake actuator, do not leave the brake fluid can in the reservoir filler opening when adding brake fluid.

Remove the bleeder plug cap of the release cylinder.

Connect a vinyl tube to the bleeder plug.

Depress the clutch pedal several times, and then loosen the bleeder plug while the pedal is depressed.

When fluid no longer comes out, tighten the bleeder plug, and then release the clutch pedal.

Repeat the previous 2 steps until all the air in the fluid is completely bled.

Tighten the bleeder plug.

Torque:

11 N*m{110 kgf*cm, 8 ft.*lbf}

Install the bleeder plug cap.

Check that all the air has been bled from the clutch line.

Check the fluid level.
If the brake fluid level is low, check for leaks and inspect the disc brake pad. If necessary, refill the reservoir with brake fluid after repair or replacement.

Brake fluid:

SAE J1703 or FMVSS No. 116 DOT 3