GSIC - Global Service Information Center

# MANUAL TRANSMISSION ASSEMBLY > REMOVAL

## for Preparation Click here

1. DISCONNECT 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 SHIFT LEVER KNOB SUB-ASSEMBLY

1. w/ M/T:
   Twist the knob in the direction indicated by the arrow and remove it.

1. w/ 4WD:
   Twist the transfer shift lever knob in the direction indicated by the arrow and remove it.

3. REMOVE UPPER CONSOLE PANEL ASSEMBLY

NOTICE:

  Be careful not to damage the instrument panel lower and console box with the claws of the console panel upper.

1. Detach the 12 claws and remove the console panel.

4. REMOVE CONSOLE BOX ASSEMBLY

1. Remove the 4 screws <F> and 2 bolts <E>.

1. Using a clip remover, remove the 2 clips and console box.

5. REMOVE SHIFT LEVER BOOT ASSEMBLY

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

6. REMOVE FLOOR SHIFT SHIFT LEVER ASSEMBLY

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.

7. REMOVE TRANSFER HIGH AND LOW SHIFT LEVER ASSEMBLY

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

   HINT:
     Move the transfer shift lever to the H4 position.

8. REMOVE TRANSFER CASE LOWER PROTECTOR

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

9. REMOVE NO. 1 ENGINE UNDER COVER

10. REMOVE NO. 2 ENGINE UNDER COVER

11. 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 }

12. REMOVE REAR PROPELLER SHAFT ASSEMBLY

1. Remove the rear propeller shaft assembly (Click here).

13. REMOVE FRONT PROPELLER SHAFT ASSEMBLY

1. Remove the front propeller shaft assembly (Click here).

14. REMOVE FRONT EXHAUST PIPE ASSEMBLY

1. Remove the front exhaust pipe assembly.
   For 1KD-FTV (Click here)
   For 2KD-FTV (Click here)
   For 2TR-FE (Click here)
   For 1GR-FE (Click here)

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 (1KD-FTV, 2KD-FTV, 2TR-FE)

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

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

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

1. Using SST, remove the flexible tube.

   SST
     09023-00100

   HINT:
     Use a container to catch the fluid.

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

   SST
     09023-00100

1. Remove the bolt and 2 way.

1. Remove the 2 bolts and the release cylinder.

1. Using SST, disconnect the 2 flexible hose tubes.

   SST
     09023-00100

18. REMOVE STARTER ASSEMBLY

1. Remove the starter assembly.
   For 1KD-FTV (Click here)
   For 2KD-FTV (Click here)
   For 2TR-FE (Click here)
   For 1GR-FE (Click here)

19. REMOVE NO. 3 FRAME CROSSMEMBER SUB-ASSEMBLY

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.

20. REMOVE REAR NO. 1 ENGINE MOUNTING INSULATOR

1. Remove the 4 bolts and engine mounting insulator.

21. REMOVE EXHAUST MANIFOLD STAY (2TR-FE)

1. Remove the 3 bolts and exhaust manifold stay.

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

1. Remove the 4 bolts and stiffener plate RH.

1. Remove the 4 bolts and stiffener plate LH.

23. REMOVE MANUAL TRANSMISSION UNIT ASSEMBLY

1. Using a transmission jack, support the transmission.

1. Remove the support stand from the rear side.

1. 1KD-FTV, 2KD-FTV:
   Remove the 5 bolts and transmission.

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

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

24. REMOVE TRANSFER ASSEMBLY

1. Remove the transfer assembly (Click here).