Manual Transmission Assembly Installation

Install the transfer (Toyota Fortuner RM000001HGT001X.html).

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

1KD-FTV:
Install the 5 bolts.

Torque:

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

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

Install the stiffener plate RH with the 4 bolts.

Torque:

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

Install the stiffener plate LH with the 4 bolts.

Torque:

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

Install the mounting insulator with the 4 bolts.

Torque:

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

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

Torque:

50 N*m{510 kgf*cm, 37 ft.*lbf}for bolt A

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

Torque:

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

Install the starter.
For 1KD-FTV, refer to the following procedures (Toyota Fortuner RM0000013XI00CX.html).
For 1GR-FE, refer to the following procedures (Toyota Fortuner RM0000013XI00DX.html).

Install the release cylinder with the 2 bolts.

Torque:

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

Install the accumulator with the 3 bolts.

Torque:

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

Using SST, connect the 2 flexible hose tubes.

SST

09023-00100

Torque:

15.5 N*m{158 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.).

Install the clutch release cylinder with the 2 bolts.

Torque:

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

Using SST, connect the flexible tube.

SST

09023-00100

Torque:

15.5 N*m{158 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.).

Install the 2 way with the bolt.

Torque:

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

Using SST, install the flexible tube.

SST

09023-00100

Torque:

15.5 N*m{158 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.).

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

Torque:

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

Transmission side:
Connect the back-up light switch connector.

Transfer side:
Connect the No. 1, No. 2 and No. 3 transfer indicator switch connectors, and vehicle speed sensor connector.

Install the front exhaust pipe.
For 1KD-FTV, refer to the following procedures (Toyota Fortuner RM000001212005X.html).
For 1GR-FE, refer to the following procedures (Toyota Fortuner RM000001216003X.html).

Install the rear propeller shaft (Toyota Fortuner RM000000ZZ1008X.html).

Install the front propeller shaft (Toyota Fortuner RM000000ZYG008X.html).

Install the transfer case lower protector with the 4 bolts.

Torque:

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

Install the transfer shift lever.

HINT:

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

Using pliers, install the snap ring.

Cover the shift lever cap with a cloth.

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.

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

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

Attach the 12 claws to install the console panel.

Twist the transmission shift lever knob in the direction indicated by the arrow to install it.

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

Check the SRS warning light (Toyota Fortuner RM000000YXW004X.html).

Bleed air from the clutch system (Toyota Fortuner RM000001FSF001X.html).

Torque:

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

Fill the master cylinder reservoir with fluid.

Check for clutch fluid leakage (Toyota Fortuner RM000001FSF001X.html).

Inspect and adjust the clutch pedal (Toyota Fortuner RM000001FS1001X.html).

Check the fluid level in the reservoir (Toyota Fortuner RM000001FSF001X_02_0004.html).