Manual Transmission Assembly Removal

Drivetrain. Land Cruiser. Urj200, 202 Grj200 Vdj200
H150F Manual Transmission Transaxle. Land Cruiser. Urj200, 202 Grj200 Vdj200

  1. PRECAUTION

  2. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL

  3. REMOVE UPPER CONSOLE PANEL SUB-ASSEMBLY

  4. REMOVE SHIFT LEVER BOOT ASSEMBLY

  5. REMOVE FLOOR SHIFT LEVER ASSEMBLY

  6. REMOVE NO. 1 ENGINE COVER SUB-ASSEMBLY (w/ Intercooler)

  7. REMOVE INTERCOOLER ASSEMBLY (w/ Intercooler)

  8. REMOVE NO. 2 COOL AIR INLET (w/o Intercooler)

  9. DRAIN CLUTCH FLUID

  10. REMOVE CLUTCH HOSE (for 1VD-FTV)

  11. REMOVE AIR TUBE SUB-ASSEMBLY LH (for 1VD-FTV)

  12. REMOVE TUBE CONNECTOR TO FLEXIBLE HOSE TUBE (for 1VD-FTV)

  13. REMOVE TRANSFER HEAT INSULATOR

  14. REMOVE TRANSFER DYNAMIC DAMPER (for 1VD-FTV)

  15. REMOVE LOWER TRANSFER CASE PROTECTOR

  16. DRAIN MANUAL TRANSMISSION OIL

  17. DRAIN TRANSFER OIL

  18. REMOVE PROPELLER SHAFT ASSEMBLY

  19. REMOVE FRONT PROPELLER SHAFT ASSEMBLY

  20. REMOVE EXHAUST PIPE (for 1GR-FE)

  21. REMOVE EXHAUST PIPE (for 1VD-FTV)

  22. REMOVE MANIFOLD STAY (for 1GR-FE)

  23. REMOVE NO. 2 MANIFOLD STAY (for 1GR-FE)

  24. REMOVE STARTER ASSEMBLY (for 1GR-FE)

  25. REMOVE NO. 2 FRAME CROSSMEMBER SUB-ASSEMBLY

  26. REMOVE REAR NO. 1 ENGINE MOUNTING INSULATOR

  27. REMOVE TRANSFER BREATHER HOSE SUB-ASSEMBLY (for 1GR-FE)

  28. REMOVE TRANSFER BREATHER HOSE SUB-ASSEMBLY (for 1VD-FTV)

  29. DISCONNECT WIRE HARNESS (for 1GR-FE)

  30. DISCONNECT WIRE HARNESS (for 1VD-FTV)

  31. REMOVE NO. 1 CLUTCH HOUSING COVER

  32. REMOVE CLUTCH RELEASE CYLINDER TO ACCUMULATOR TUBE

  33. REMOVE CLUTCH ACCUMULATOR ASSEMBLY

  34. REMOVE CLUTCH RELEASE CYLINDER ASSEMBLY

  35. REMOVE CLUTCH RELEASE CYLINDER TO FLEXIBLE HOSE TUBE

  36. REMOVE OIL PAN COVER (for 1VD-FTV)

  37. REMOVE MANUAL TRANSMISSION WITH TRANSFER (for 1GR-FE)

  38. REMOVE MANUAL TRANSMISSION WITH TRANSFER (for 1VD-FTV)

  39. REMOVE TRANSFER ASSEMBLY

  40. REMOVE CLUTCH RELEASE FORK SUB-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 (Click here)


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


3. REMOVE UPPER CONSOLE PANEL SUB-ASSEMBLY
w/o Console Box Lid (Click here)
w/ Cool Box (Click here)
w/o Cool Box (Click here)


4. REMOVE SHIFT LEVER BOOT ASSEMBLY


Land Cruiser. Urj200, 202 Grj200 Vdj200

  1. Remove the 4 screws, shift lever retainer and shift lever boot.



5. REMOVE FLOOR SHIFT LEVER ASSEMBLY


Land Cruiser. Urj200, 202 Grj200 Vdj200.H150F Manual Transmission Transaxle.Manual Transmission System.Manual Transmission Assembly Removal

  1. Cover the shift lever cap with a cloth.

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

  1. Pull out the shift lever.



6. REMOVE NO. 1 ENGINE COVER SUB-ASSEMBLY (w/ Intercooler)


    Land Cruiser. Urj200, 202 Grj200 Vdj200

  1. Remove the 2 nuts and No. 1 engine cover.



7. REMOVE INTERCOOLER ASSEMBLY (w/ Intercooler)


    Land Cruiser. Urj200, 202 Grj200 Vdj200

  1. Loosen the No. 1 air hose clamp.



    Land Cruiser. Urj200, 202 Grj200 Vdj200

  1. Loosen the No. 2 air hose clamp.



    Land Cruiser. Urj200, 202 Grj200 Vdj200

  1. Disconnect the turbo pressure sensor connector, intake air temperature sensor connector and vacuum hose.



    Land Cruiser. Urj200, 202 Grj200 Vdj200

  1. Remove the 6 nuts, 2 bolts and intercooler.

  1. Remove the 2 gaskets from the air tube LH and RH.



8. REMOVE NO. 2 COOL AIR INLET (w/o Intercooler)


    Land Cruiser. Urj200, 202 Grj200 Vdj200

  1. Loosen the No. 2 air hose clamp.



    Land Cruiser. Urj200, 202 Grj200 Vdj200

  1. Remove the 3 nuts, bolt and No. 2 cool air inlet.

  1. Remove the gasket from the air tube LH.



9. DRAIN CLUTCH FLUID


10. REMOVE CLUTCH HOSE (for 1VD-FTV)


    Land Cruiser. Urj200, 202 Grj200 Vdj200

  1. Disconnect the 2 flexible hose tubes from the clutch hose with a 10 mm union nut wrench while holding the flexible hose with a wrench.

    NOTICE:
    1. Do not bend or damage the flexible hose tubes.
    2. Do not allow any foreign matter such as dirt and dust to enter the flexible hose tubes from the connecting point.

  1. Remove the 2 clips.



    Land Cruiser. Urj200, 202 Grj200 Vdj200

  1. Remove the bolt and clutch hose.



11. REMOVE AIR TUBE SUB-ASSEMBLY LH (for 1VD-FTV)


    Land Cruiser. Urj200, 202 Grj200 Vdj200

  1. Loosen the hose clamp.

  1. Remove the air tube from the throttle body.



12. REMOVE TUBE CONNECTOR TO FLEXIBLE HOSE TUBE (for 1VD-FTV)


    Land Cruiser. Urj200, 202 Grj200 Vdj200

  1. Using a 10 mm union nut wrench, disconnect the tube connector to flexible hose tube from the clutch tube to release cylinder 2 way.

    NOTICE:
    1. Do not bend or damage the flexible hose tube.
    2. Do not allow any foreign matter such as dirt and dust to enter the flexible hose tube from the connecting point.


    Land Cruiser. Urj200, 202 Grj200 Vdj200

  1. Remove the 2 bolts and tube connector to flexible hose tube.



13. REMOVE TRANSFER HEAT INSULATOR


    Land Cruiser. Urj200, 202 Grj200 Vdj200

  1. Remove the 4 bolts and insulator.



14. REMOVE TRANSFER DYNAMIC DAMPER (for 1VD-FTV)


Land Cruiser. Urj200, 202 Grj200 Vdj200

  1. Remove the 2 bolts and transfer dynamic damper.



15. REMOVE LOWER TRANSFER CASE PROTECTOR


Land Cruiser. Urj200, 202 Grj200 Vdj200

  1. Remove the 7 bolts and lower transfer case protector.



16. DRAIN MANUAL TRANSMISSION OIL


Land Cruiser. Urj200, 202 Grj200 Vdj200

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



    Land Cruiser. Urj200, 202 Grj200 Vdj200

  1. Remove the filler plug and gasket.

  1. Install a new gasket and the drain plug.

    Torque:
    37 N*m{380 kgf*cm, 27 ft.*lbf}


17. DRAIN TRANSFER OIL


    Land Cruiser. Urj200, 202 Grj200 Vdj200

  1. except 1GR-FE:
    Remove the 2 bolts and transfer dynamic damper.



    Land Cruiser. Urj200, 202 Grj200 Vdj200

  1. Remove the 4 bolts and transfer heat insulator.



    Land Cruiser. Urj200, 202 Grj200 Vdj200

  1. Remove the 7 bolts and lower transfer case protector.



    Land Cruiser. Urj200, 202 Grj200 Vdj200

  1. Remove the filler plug and gasket.



    Land Cruiser. Urj200, 202 Grj200 Vdj200

  1. Remove the drain plug and gasket, and drain the transfer oil.



18. REMOVE PROPELLER SHAFT ASSEMBLY
(Click here)


19. REMOVE FRONT PROPELLER SHAFT ASSEMBLY
(Click here)


20. REMOVE EXHAUST PIPE (for 1GR-FE)
(Click here)


21. REMOVE EXHAUST PIPE (for 1VD-FTV)
w/o DPF: (Click here)
w/ DPF: (Click here)


22. REMOVE MANIFOLD STAY (for 1GR-FE)


    Land Cruiser. Urj200, 202 Grj200 Vdj200

  1. Remove the 3 bolts and manifold stay.



23. REMOVE NO. 2 MANIFOLD STAY (for 1GR-FE)


    Land Cruiser. Urj200, 202 Grj200 Vdj200

  1. Remove the 3 bolts and No. 2 manifold stay.



24. REMOVE STARTER ASSEMBLY (for 1GR-FE)
(Click here)


25. REMOVE NO. 2 FRAME CROSSMEMBER SUB-ASSEMBLY

  1. Support the transmission with a transmission jack. Lift the transmission slightly from the crossmember.



    Land Cruiser. Urj200, 202 Grj200 Vdj200

  1. Remove the 4 bolts of the rear engine mounting insulator.



    Land Cruiser. Urj200, 202 Grj200 Vdj200

  1. Remove the 4 bolts, 4 nuts, 4 washers and frame crossmember.



26. REMOVE REAR NO. 1 ENGINE MOUNTING INSULATOR


    Land Cruiser. Urj200, 202 Grj200 Vdj200

  1. Remove the 4 bolts and engine mounting insulator.



27. REMOVE TRANSFER BREATHER HOSE SUB-ASSEMBLY (for 1GR-FE)


    Land Cruiser. Urj200, 202 Grj200 Vdj200

  1. Disconnect the breather hose from the transfer and actuator, and disconnect the 2 clamps.



    Land Cruiser. Urj200, 202 Grj200 Vdj200

  1. Disconnect the 5 clamps.



    Land Cruiser. Urj200, 202 Grj200 Vdj200

  1. Disconnect the 2 breather hoses from the bracket.



28. REMOVE TRANSFER BREATHER HOSE SUB-ASSEMBLY (for 1VD-FTV)


    Land Cruiser. Urj200, 202 Grj200 Vdj200

  1. Disconnect the breather hose from the transfer and actuator, and disconnect the 2 clamps.



    Land Cruiser. Urj200, 202 Grj200 Vdj200

  1. Disconnect the 3 clamps.



    Land Cruiser. Urj200, 202 Grj200 Vdj200

  1. Disconnect the 3 breather hoses from the bracket.

  1. Remove the bolt and disconnect the bracket from the transmission.



29. DISCONNECT WIRE HARNESS (for 1GR-FE)


    Land Cruiser. Urj200, 202 Grj200 Vdj200

  1. Disconnect the 2 connectors and 3 clamps.



    Land Cruiser. Urj200, 202 Grj200 Vdj200

  1. Remove the bolt and disconnect the ground cable.

  1. Tilt the transmission downward.

    NOTICE:
    Make sure the cooling fan does not contact the fan shroud.


    Land Cruiser. Urj200, 202 Grj200 Vdj200.H150F Manual Transmission Transaxle.Manual Transmission System.Manual Transmission Assembly Removal

  1. Remove the 2 bolts.

  1. Disconnect the back-up light switch connector.

  1. Disconnect the 6 clamps.



30. DISCONNECT WIRE HARNESS (for 1VD-FTV)


    Land Cruiser. Urj200, 202 Grj200 Vdj200

  1. Disconnect the 2 connectors and 3 clamps.



    Land Cruiser. Urj200, 202 Grj200 Vdj200

  1. Remove the bolt and disconnect the ground cable.

  1. Tilt the transmission downward.

    NOTICE:
    Make sure the cooling fan does not contact the fan shroud.


    Land Cruiser. Urj200, 202 Grj200 Vdj200

  1. Disconnect the shift position switch connector.

  1. Disconnect the back-up light switch connector.

  1. Disconnect the 5 clamps.



31. REMOVE NO. 1 CLUTCH HOUSING COVER


Land Cruiser. Urj200, 202 Grj200 Vdj200

  1. Remove the 3 bolts and clutch housing cover.



32. REMOVE CLUTCH RELEASE CYLINDER TO ACCUMULATOR TUBE


Land Cruiser. Urj200, 202 Grj200 Vdj200

  1. Using a union nut wrench, disconnect the tube.

    HINT:
    Use a container to catch the fluid.

  1. Remove the 2 bolts and tube.



33. REMOVE CLUTCH ACCUMULATOR ASSEMBLY


Land Cruiser. Urj200, 202 Grj200 Vdj200

  1. Using a union nut wrench, disconnect the flexible hose tube.

    HINT:
    Use a container to catch the fluid.


    Land Cruiser. Urj200, 202 Grj200 Vdj200

  1. Remove the 3 bolts and clutch accumulator.



34. REMOVE CLUTCH RELEASE CYLINDER ASSEMBLY


Land Cruiser. Urj200, 202 Grj200 Vdj200

  1. Remove the 2 bolts and pull out the clutch release cylinder.



35. REMOVE CLUTCH RELEASE CYLINDER TO FLEXIBLE HOSE TUBE


Land Cruiser. Urj200, 202 Grj200 Vdj200.H150F Manual Transmission Transaxle.Manual Transmission System.Manual Transmission Assembly Removal

  1. Remove the 3 bolts and flexible hose tube.



36. REMOVE OIL PAN COVER (for 1VD-FTV)


Land Cruiser. Urj200, 202 Grj200 Vdj200

  1. Remove the 2 bolts and oil pan cover.



37. REMOVE MANUAL TRANSMISSION WITH TRANSFER (for 1GR-FE)


Land Cruiser. Urj200, 202 Grj200 Vdj200

  1. Remove the 9 bolts and manual transmission with transfer.



38. REMOVE MANUAL TRANSMISSION WITH TRANSFER (for 1VD-FTV)


Land Cruiser. Urj200, 202 Grj200 Vdj200

  1. Remove the 10 bolts and manual transmission with transfer.



39. REMOVE TRANSFER ASSEMBLY


    Land Cruiser. Urj200, 202 Grj200 Vdj200.H150F Manual Transmission Transaxle.Manual Transmission System.Manual Transmission Assembly Removal

  1. Remove the 8 transfer adaptor rear mounting bolts.

  1. Pull the transfer straight up and remove it from the transmission.

    NOTICE:
    Take care not to damage the adaptor oil seal with the transfer input shaft spline.


40. REMOVE CLUTCH RELEASE FORK SUB-ASSEMBLY


Land Cruiser. Urj200, 202 Grj200 Vdj200

  1. Remove the clutch release fork with the clutch release bearing from the transmission unit.

  1. Remove the release fork support from the transmission unit.



    Land Cruiser. Urj200, 202 Grj200 Vdj200

  1. Remove the clip and release bearing from the clutch release fork.