Manual Transmission Assembly Installation

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

for KD series:
Install the 5 bolts.

Torque:

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

for 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:

47 N*m{479 kgf*cm, 35 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 rear No. 1 engine mounting insulator.

Torque:

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

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

Install the clutch 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

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

Install the 2 way with the bolt.

Torque:

19 N*m{194 kgf*cm, 14 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 release cylinder heat insulator with the bolt and nut.

Torque:

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

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

Install the front exhaust pipe.
For KD series, refer to the following procedures (Toyota Fortuner RM000001212005X_01_0001.html).
For 1GR-FE, refer to the following procedures (Toyota Fortuner RM000001216003X_01_0001.html).

Install the rear propeller shaft (Toyota Fortuner RM000000ZZ1008X_01_0002.html).

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

Torque:

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

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.

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).

Lift up the floor carpet to expose the asphalt sheet under the pedal.

Check that the pedal height is correct.

Standard pedal height from dash panel:

179.6 to 189.6 mm (7.070 to 7.464 in.)

Adjust the pedal height.

1. Loosen the lock nut and turn the stopper bolt until the pedal height is within the specified range.
   

2. Tighten the lock nut.
   

   Torque:

   25 N*m{255 kgf*cm, 18 ft.*lbf}

Check the pedal free play and push rod play.

1. Depress the clutch pedal until resistance is felt.
   

2. Measure the distance between the pedal's released position and the position in the previous step.
   

   Standard pedal free play:

   5.0 to 15.0 mm (0.197 to 0.591 in.)
   

3. Release the pedal. Using your finger, gently press the pedal until resistance increases slightly.
   

4. Measure the distance between the pedal's released position and the position in the previous step.
   

   Standard push rod play at top of pedal:

   1.0 to 5.0 mm (0.039 to 0.197 in.)
   

Adjust the pedal free play and push rod play.

1. Loosen the lock nut and turn the push rod until the pedal free play and push rod play are within the specified ranges.
   

2. Tighten the lock nut.
   

   Torque:

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

3. After adjusting the pedal free play, check the pedal height.
   

Check the clutch release point.

1. Pull the parking brake lever and use wheel chocks to stabilize the vehicle.
   

2. Start the engine and run it at idle.
   

3. Without depressing the clutch pedal, slowly move the shift lever to R until the gears contact.
   

4. Gently depress the clutch pedal and measure the stroke distance from the point that the gear noise stops (release point) up to the full stroke end position.
   

   Standard distance (A):

   30 mm (1.180 in.) or more
   

   If the distance is not as specified, perform the following operations.
   
   1. Check pedal height.
      
   2. Check push rod play and pedal free play.
      
   3. Bleed air from clutch line.
      
   4. Check clutch cover and disc.
      

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