MANUAL TRANSMISSION ASSEMBLY > REMOVAL

for Preparation Click here



1. REMOVE CABLE FROM NEGATIVE BATTERY TERMINAL

CAUTION:
Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag and seat belt pretensioner activation.


2. REMOVE CONSOLE BOX ASSEMBLY
(Click here)


3. REMOVE SHIFT LEVER BOOT ASSEMBLY


G034215E03
  1. w/o Console Box:
    Remove the front seat, front door scuff plate, etc. and fold back the floor carpet so that the shift lever can be removed.

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



4. REMOVE FLOOR SHIFT SHIFT LEVER ASSEMBLY


G021695E01
  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.



5. REMOVE NO. 1 ENGINE UNDER COVER


6. REMOVE NO. 2 ENGINE UNDER COVER


7. DRAIN MANUAL TRANSMISSION OIL
  1. Remove the drain plug and gasket to drain the oil.

  1. Install a new gasket and the drain plug.

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


8. REMOVE NO. 2 FRAME CROSSMEMBER ASSEMBLY


D033401E01
  1. Remove the 4 bolts, 4 nuts and frame crossmember.



9. REMOVE REAR PROPELLER SHAFT ASSEMBLY
for TSAM Made: (Click here)
for TMT Made: (Click here)


10. REMOVE FRONT EXHAUST PIPE ASSEMBLY
for 2TR-FE: (Click here)
for 1GR-FE: (Click here)
for 1KD-FTV: (Click here)
for 2KD-FTV: (Click here)
for 2KD-FTV for DPF: (Click here)


11. DISCONNECT WIRE HARNESS
  1. Disconnect the back-up light switch connector and speedometer sensor connector.



12. DISCONNECT CLUTCH RELEASE CYLINDER ASSEMBLY (for 1KD-FTV, 2TR-FE)


G034217E01
  1. Remove the 2 bolts and disconnect the release cylinder assembly.



13. REMOVE CLUTCH RELEASE CYLINDER ASSEMBLY (for 1GR-FE)


C112617
  1. Remove the bolts, nut and release cylinder heat insulator.



    C112615
  1. Using a union nut wrench, remove the flexible tube.

    HINT:
    Use a container to catch the fluid.


    C112616
  1. Disconnect the clutch release cylinder to flexible hose tube.

  1. Remove the bolt and 2 way.



    C112662
  1. Remove the 2 bolts and release cylinder.



    D030415E03
  1. Using a union nut wrench, disconnect the 2 flexible hose tubes.



14. REMOVE STARTER ASSEMBLY
for 2TR-FE 1.4 kW Type: (Click here)
for 2TR-FE 1.6 kW Type: (Click here)
for 2TR-FE 1.7 kW Type: (Click here)
for 1GR-FE: (Click here)
for 1KD-FTV 2.2 kW Type Bosch Made: (Click here)
for 1KD-FTV 2.2 kW Type Denso Made: (Click here)
for 2KD-FTV 2.2 kW Type: (Click here)
for 2KD-FTV 2.7 kW Type: (Click here)


15. REMOVE NO. 3 FRAME CROSSMEMBER SUB-ASSEMBLY


B085193E04
  1. Support the transmission rear side with a support stand.

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

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



16. REMOVE REAR NO. 1 ENGINE MOUNTING INSULATOR


G034219E02
  1. Remove the 4 bolts and mounting insulator.



17. REMOVE EXHAUST MANIFOLD STAY (for 2TR-FE)


B086194E01
  1. Remove the 3 bolts and exhaust manifold stay.



18. REMOVE STIFFENER PLATE (for 1KD-FTV)


G034607E01
  1. Remove the 4 bolts and stiffener plate RH.

  1. Remove the 4 bolts and stiffener plate LH.



19. REMOVE MANUAL TRANSMISSION UNIT ASSEMBLY


C113299E03
  1. Using a transmission jack, support the transmission.

  1. Remove the support stand from the rear side.

  1. for 1KD-FTV:
    Remove the 5 bolts and transmission.

  1. for 2TR-FE:
    Remove the 7 bolts and transmission.

  1. for 1GR-FE:
    Remove the 9 bolts and transmission.