Manual Transmission Assembly -- Installation |
| 1. INSTALL TRANSFER ASSEMBLY |
Install the transfer to the transmission.
Install the clamp and 8 bolts.
- Torque:
- 24 N*m{244 kgf*cm, 17 ft.*lbf}
| 2. INSTALL MANUAL TRANSMISSION UNIT ASSEMBLY |
Make sure that the knock pins are not loose, bent, damaged or scratched.
Align the input shaft with the clutch disc and install the transmission to the engine.
Text in Illustration *A for 2TR-FE *B for 1KD-FTV, 2KD-FTV
 |
Install the 5 bolts.
- Torque:
- 72 N*m{729 kgf*cm, 53 ft.*lbf}
| 3. INSTALL STIFFENER PLATE (for 1KD-FTV, 2KD-FTV) |
Install the stiffener plate RH with the 4 bolts.
- Torque:
- 72 N*m{729 kgf*cm, 53 ft.*lbf}
Install the stiffener plate LH with the 4 bolts.
- Torque:
- 72 N*m{729 kgf*cm, 53 ft.*lbf}
| 4. INSTALL MANIFOLD STAY (for TR Series Engine) |
| 5. INSTALL REAR NO. 1 ENGINE MOUNTING INSULATOR |
Install the mounting insulator with the 4 bolts.
- Torque:
- 47 N*m{479 kgf*cm, 35 ft.*lbf}
| 6. INSTALL NO. 3 FRAME CROSSMEMBER SUB-ASSEMBLY |
Install the No. 3 frame crossmember sub-assembly with the 4 bolts and 4 nuts.
- Torque:
- 50 N*m{510 kgf*cm, 37 ft.*lbf}
Connect the No. 3 frame crossmember sub-assembly to the No. 1 rear engine mounting insulator.
- Torque:
- 27 N*m{275 kgf*cm, 20 ft.*lbf}
| 7. INSTALL STARTER ASSEMBLY |
for 2TR-FE 1.7kW Type: (HILUX_TGN26 RM000000SGZ015X.html)
for 1KD-FTV DENSO made: (HILUX_TGN26 RM0000013XI03EX.html)
for 1KD-FTV BOSCH made: (HILUX_TGN26 RM0000013XI03FX.html)
for 2KD-FTV DENSO made: (HILUX_TGN26 RM0000013XI03GX.html)
for 2KD-FTV BOSCH made: (HILUX_TGN26 RM0000013XI03HX.html)
| 8. CONNECT CLUTCH RELEASE CYLINDER ASSEMBLY |
Install the clutch release cylinder with the 2 bolts.
- Torque:
- 12 N*m{119 kgf*cm, 9 ft.*lbf}
| 9. CONNECT WIRE HARNESS |
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.
| 10. INSTALL FRONT EXHAUST PIPE ASSEMBLY |
for 1KD-FTV w/o DPF: (HILUX_TGN26 RM00000121201DX.html)
for 1KD-FTV w/DPF: (HILUX_TGN26 RM00000456800CX.html)
for 2KD-FTV w/o DPF: (HILUX_TGN26 RM00000121201EX.html)
for 2KD-FTV w/DPF: (HILUX_TGN26 RM00000456800DX.html)
| 11. INSTALL PROPELLER WITH CENTER BEARING SHAFT ASSEMBLY |
| 12. INSTALL FRONT PROPELLER SHAFT ASSEMBLY |
| 13. ADD MANUAL TRANSMISSION OIL |
Add manual transmission oil until the oil level is within 5 mm (0.196 in.) from the bottom of the filler plug opening.
Text in Illustration *a 0 to 5 mm (0 to 0.196 in.) - Oil grade:
- GL-4 or GL-5
- Viscosity:
- SAE 75W-90, 80 or 80W-90
- Standard capacity:
- 2.2 liters (2.3 US qts, 1.9 Imp. qts)
 |
Install a new gasket and the filler plug.
- Torque:
- 37 N*m{377 kgf*cm, 27 ft.*lbf}
| 14. ADD TRANSFER OIL |
Add transfer oil until the oil level is within 5 mm (0.196 in.) from the bottom of the transmission filler plug opening.
Install a new gasket to the filler plug, and then install the plug.
- Torque:
- 37 N*m{377 kgf*cm, 27 ft.*lbf}
- NOTICE:
- When adding transfer oil, make sure the vehicle is level.
- An excessively large or small amount of oil may cause problems.
- After adding oil, drive the vehicle and recheck the oil level.
Inspect for transfer oil leaks.
| 15. REMOVE NO. 3 ENGINE UNDER COVER |
- Torque:
- 28 N*m{286 kgf*cm, 21 ft.*lbf}
| 16. INSTALL NO. 2 ENGINE UNDER COVER |
- Torque:
- 28 N*m{286 kgf*cm, 21 ft.*lbf}
| 17. INSTALL NO. 1 ENGINE UNDER COVER |
- Torque:
- 28 N*m{286 kgf*cm, 21 ft.*lbf}
| 18. INSTALL TRANSFER CASE LOWER PROTECTOR |
Install the transfer case lower protector with the 4 bolts.
- Torque:
- 18 N*m{183 kgf*cm, 13 ft.*lbf}
| 19. INSTALL TRANSFER HIGH AND LOW SHIFT LEVER ASSEMBLY |
Install the transfer shift lever.
Using pliers, install the snap ring.
- HINT:
- Apply MP grease to the tip of the transfer shift lever.
| 20. INSTALL FLOOR SHIFT LEVER ASSEMBLY |
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.
| 21. INSTALL SHIFT LEVER BOOT ASSEMBLY |
Install the shift lever boot with the 4 screws and 2 clips.
| 22. INSTALL CONSOLE BOX ASSEMBLY |
| 23. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL |
- NOTICE:
- When disconnecting the cable, some systems need to be initialized after the cable is reconnected (HILUX_TGN26 RM000004QR3009X.html).