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 RM000004QR1006X.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 RM000004QR3009X.html).
| 3. REMOVE CONSOLE BOX ASSEMBLY |
| 4. REMOVE SHIFT LEVER BOOT ASSEMBLY |
Remove the 4 screws, 2 clips and shift lever boot assembly.
Text in Illustration *1 Screw *2 Clip
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| 5. REMOVE FLOOR SHIFT SHIFT LEVER ASSEMBLY |
Cover the shift lever cap with a cloth.
Text in Illustration *1 Cloth *a Press down *b Rotate Counterclockwise
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Press down on the shift lever cap and rotate it counterclockwise to remove it.
Pull out the shift lever.
| 6. REMOVE TRANSFER HIGH AND LOW SHIFT LEVER ASSEMBLY |
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 |
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 |
Remove the filler plug and gasket.
Remove the drain plug and gasket to drain the manual transmission oil.
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 |
| 13. REMOVE FRONT PROPELLER SHAFT ASSEMBLY |
| 14. REMOVE FRONT EXHAUST PIPE ASSEMBLY |
for 1KD-FTV w/o DPF: (HILUX_TGN26 RM00000121301DX.html)
for 1KD-FTV w/ DPF: (HILUX_TGN26 RM00000456A00CX.html)
for 2KD-FTV w/o DPF: (HILUX_TGN26 RM00000121301EX.html)
for 2KD-FTV w/DPF: (HILUX_TGN26 RM00000456A00DX.html)
| 15. DISCONNECT WIRE HARNESS |
Transmission side:
Disconnect the back-up light switch connector.
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 |
Remove the 2 bolts and disconnect the release cylinder assembly.
 |
| 17. REMOVE STARTER ASSEMBLY |
for 2TR-FE 1.7kW Type: (HILUX_TGN26 RM000000SH2014X.html)
for 1KD-FTV DENSO made: (HILUX_TGN26 RM0000013XL03CX.html)
for 1KD-FTV BOSCH made: (HILUX_TGN26 RM0000013XL03DX.html)
for 2KD-FTV DENSO made: (HILUX_TGN26 RM0000013XL03EX.html)
for 2KD-FTV BOSCH made: (HILUX_TGN26 RM0000013XL03FX.html)
| 18. REMOVE NO. 3 FRAME CROSSMEMBER SUB-ASSEMBLY |
Support the transmission rear side with a support stand.
Remove the 4 set bolts of the rear No. 1 engine mounting insulator.
 |
Remove the 4 bolts, 4 nuts and No. 3 frame crossmember sub-assembly.
| 19. REMOVE REAR NO. 1 ENGINE MOUNTING INSULATOR |
Remove the 4 bolts and mounting insulator.
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| 20. REMOVE MANIFOLD STAY (for TR Series Engine) |
Remove the 3 bolts and manifold stay.
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| 21. REMOVE STIFFENER PLATE (for 1KD-FTV, 2KD-FTV) |
Remove the 4 bolts and stiffener plate RH.
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Remove the 4 bolts and stiffener plate LH.
| 22. REMOVE MANUAL TRANSMISSION UNIT ASSEMBLY |
Using a transmission jack, support the transmission.
Remove the support stand from the transmission.
Text in Illustration *A for 2TR-FE *B for 1KD-FTV, 2KD-FTV
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Remove the 5 bolts and transmission.
| 23. REMOVE TRANSFER ASSEMBLY |
Remove the 8 bolts and 2 clamps.
Remove the transfer from the transmission.
- NOTICE:
- Do not damage the lip of the transfer adaptor oil seal.