Manual Transmission Assembly Removal

Drivetrain. Hilux. Tgn26, 36 Kun25, 26, 35, 36 Ggn25
R150Fr151F R156F Manual Transmission Transaxle. Hilux. Tgn26, 36 Kun25, 26, 35, 36 Ggn25

  1. PRECAUTION

  2. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL

  3. REMOVE CONSOLE BOX ASSEMBLY

  4. REMOVE SHIFT LEVER BOOT ASSEMBLY

  5. REMOVE FLOOR SHIFT SHIFT LEVER ASSEMBLY

  6. REMOVE TRANSFER HIGH AND LOW SHIFT LEVER ASSEMBLY

  7. REMOVE TRANSFER CASE LOWER PROTECTOR

  8. REMOVE NO. 1 ENGINE UNDER COVER

  9. REMOVE NO. 2 ENGINE UNDER COVER

  10. REMOVE NO. 3 ENGINE UNDER COVER

  11. DRAIN MANUAL TRANSMISSION OIL

  12. REMOVE PROPELLER WITH CENTER BEARING SHAFT ASSEMBLY

  13. REMOVE FRONT PROPELLER SHAFT ASSEMBLY

  14. REMOVE FRONT EXHAUST PIPE ASSEMBLY

  15. DISCONNECT WIRE HARNESS

  16. DISCONNECT CLUTCH RELEASE CYLINDER ASSEMBLY

  17. REMOVE STARTER ASSEMBLY

  18. REMOVE NO. 3 FRAME CROSSMEMBER SUB-ASSEMBLY

  19. REMOVE REAR NO. 1 ENGINE MOUNTING INSULATOR

  20. REMOVE MANIFOLD STAY (for TR Series Engine)

  21. REMOVE STIFFENER PLATE (for 1KD-FTV, 2KD-FTV)

  22. REMOVE MANUAL TRANSMISSION UNIT ASSEMBLY

  23. REMOVE TRANSFER ASSEMBLY

Manual Transmission Assembly -- Removal



1. PRECAUTION
NOTICE:
After turning the ignition switch off, waiting time may be required before disconnecting the cable from the battery terminal. Therefore, make sure to read the disconnecting the cable from the battery terminal notice before proceeding with work (HILUX_TGN26 RM000004QR1003X.html)


2. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL
NOTICE:
When disconnecting the cable, some systems need to be initialized after the cable is reconnected (HILUX_TGN26 RM000004QR3003X.html).


3. REMOVE CONSOLE BOX ASSEMBLY
(HILUX_TGN26 RM000003NEC00QX.html)


4. REMOVE SHIFT LEVER BOOT ASSEMBLY


    Hilux. Tgn26, 36 Kun25, 26, 35, 36 Ggn25.R150Fr151F R156F Manual Transmission Transaxle.Manual Transmission System.Manual Transmission Assembly Removal

  1. Remove the 4 screws, 2 clips and shift lever boot assembly.

    Text in Illustration
    *1
    		Screw
    *2
    		Clip


5. REMOVE FLOOR SHIFT SHIFT LEVER ASSEMBLY


    Hilux. Tgn26, 36 Kun25, 26, 35, 36 Ggn25.R150Fr151F R156F Manual Transmission Transaxle.Manual Transmission System.Manual Transmission Assembly Removal

  1. Cover the shift lever cap with a cloth.

    Text in Illustration
    *1
    		Cloth
    *a
    		Press down
    *b
    		Rotate Counterclockwise

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

  1. Pull out the shift lever.



6. REMOVE TRANSFER HIGH AND LOW SHIFT LEVER ASSEMBLY


    Hilux. Tgn26, 36 Kun25, 26, 35, 36 Ggn25.R150Fr151F R156F Manual Transmission Transaxle.Manual Transmission System.Manual Transmission Assembly Removal

  1. Using needle nose pliers, remove the snap ring and pull out the shift lever.

    Text in Illustration
    *1
    		Select Return Spring
    *a
    		Tip of Shift Lever
    HINT:
    Move the transfer shift lever to the H4 position.


7. REMOVE TRANSFER CASE LOWER PROTECTOR

  1. Remove the 4 bolts and transfer case lower protector.



8. REMOVE NO. 1 ENGINE UNDER COVER


9. REMOVE NO. 2 ENGINE UNDER COVER


10. REMOVE NO. 3 ENGINE UNDER COVER


11. DRAIN MANUAL TRANSMISSION OIL

  1. Remove the filler plug and gasket.

  1. Remove the drain plug and gasket to drain the manual transmission oil.

  1. Install a new gasket and the drain plug.

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


12. REMOVE PROPELLER WITH CENTER BEARING SHAFT ASSEMBLY
(HILUX_TGN26 RM000000ZZ301QX.html)


13. REMOVE FRONT PROPELLER SHAFT ASSEMBLY
(HILUX_TGN26 RM0000010QG00XX.html)


14. REMOVE FRONT EXHAUST PIPE ASSEMBLY
for 2TR-FE: (HILUX_TGN26 RM00000135901FX.html)
for 1KD-FTV: (HILUX_TGN26 RM00000121301DX.html)
for 2KD-FTV: (HILUX_TGN26 RM00000121301EX.html)


15. DISCONNECT WIRE HARNESS

  1. Transmission side:
    Disconnect the back-up light switch connector.

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



16. DISCONNECT CLUTCH RELEASE CYLINDER ASSEMBLY


    Hilux. Tgn26, 36 Kun25, 26, 35, 36 Ggn25.R150Fr151F R156F Manual Transmission Transaxle.Manual Transmission System.Manual Transmission Assembly Removal

  1. Remove the 2 bolts and disconnect the release cylinder assembly.



17. REMOVE STARTER ASSEMBLY
for 2TR-FE 1.6kW Type: (HILUX_TGN26 RM00000135T01AX.html )
for 2TR-FE 1.7kW Type: (HILUX_TGN26 RM000000SH200RX.html)
for 1KD-FTV DENSO made: (HILUX_TGN26 RM0000013XL02LX.html)
for 1KD-FTV BOSCH made: (HILUX_TGN26 RM0000013XL02NX.html)
for 2KD-FTV DENSO made: (HILUX_TGN26 RM0000013XL02MX.html)
for 2KD-FTV BOSCH made: (HILUX_TGN26 RM0000013XL02OX.html)


18. REMOVE NO. 3 FRAME CROSSMEMBER SUB-ASSEMBLY

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



    Hilux. Tgn26, 36 Kun25, 26, 35, 36 Ggn25.R150Fr151F R156F Manual Transmission Transaxle.Manual Transmission System.Manual Transmission Assembly Removal

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

  1. Remove the 4 bolts, 4 nuts and No. 3 frame crossmember sub-assembly.



19. REMOVE REAR NO. 1 ENGINE MOUNTING INSULATOR


    Hilux. Tgn26, 36 Kun25, 26, 35, 36 Ggn25.R150Fr151F R156F Manual Transmission Transaxle.Manual Transmission System.Manual Transmission Assembly Removal

  1. Remove the 4 bolts and mounting insulator.



20. REMOVE MANIFOLD STAY (for TR Series Engine)


    Hilux. Tgn26, 36 Kun25, 26, 35, 36 Ggn25

  1. Remove the 3 bolts and manifold stay.



21. REMOVE STIFFENER PLATE (for 1KD-FTV, 2KD-FTV)


    Hilux. Tgn26, 36 Kun25, 26, 35, 36 Ggn25.R150Fr151F R156F Manual Transmission Transaxle.Manual Transmission System.Manual Transmission Assembly Removal

  1. Remove the 4 bolts and stiffener plate RH.

  1. Remove the 4 bolts and stiffener plate LH.



22. REMOVE MANUAL TRANSMISSION UNIT ASSEMBLY

  1. Using a transmission jack, support the transmission.



    Hilux. Tgn26, 36 Kun25, 26, 35, 36 Ggn25.R150Fr151F R156F Manual Transmission Transaxle.Manual Transmission System.Manual Transmission Assembly Removal

  1. Remove the support stand from the transmission.

    Text in Illustration
    *A
    		for 2TR-FE
    *B
    		for 1KD-FTV, 2KD-FTV

  1. Remove the 5 bolts and transmission.



23. REMOVE TRANSFER ASSEMBLY

  1. Remove the 8 bolts and 2 clamps.

  1. Remove the transfer from the transmission.

    NOTICE:
    Do not damage the lip of the transfer adaptor oil seal.