Installation

INSTALLATION OF TRANSMISSION

1. INSTALL TRANSFER AND PROPELLER SHAFT UPPER DUST COVER TO TRANSMISSION WITH NEW GASKET





- Shift the two shift fork shafts to the high-four position.





- Apply MP grease to the adaptor oil seal.
- Place a new gasket to the transfer adaptor.
- Install the transfer to the transmission.

HINT: Take care not to damage the oil seal by the input gear spline when installing the transfer.





- Install and torque the bolts with the propeller shaft upper dust cover.

Torque:
W56 400 kg.cm (29 ft.lb, 39 N.m)
R15OF, G58 380 kg.cm (27 ft-lb, 37 N.m)

- Install the dust cover bolt to the bracket.

Torque:
R15OF, G58 230 kg.cm (17 ft.lb, 23 N.m)
W56 400 kg.cm (29 ft-lb, 39 N.m)





2. INSTALL ENGINE REAR MOUNTING

Torque: 260 kg.cm (19 ft.lb, 25 N.m)





3. (Regular Cab w/Planetary Gear Type Transfer)
INSTALL DYNAMIC DAMPER

Torque: 380 kg.cm (27 ft.lb, 37 N.m)





4. (22R-E/G58)
INSTALL BREATHER HOSE
- Connect the breather hose for transfer upper cover and transmission control retainer as shown.

Hose depth: 13 mm (0.51 in.)

5. PLACE TRANSMISSION WITH TRANSFER AT INSTALLATION POSITION
- Support the transmission with a jack.
- Align the input shaft spline with the clutch disc, and push the transmission with the transfer fully into position.





6. -1 (3VZ-E)
INSTALL TRANSMISSION BOLTS, STIFFENER BOLTS AND STARTER

Torque:
(A) Transmission bolt: 730 kg.cm (53 ft.lb, 72 N.m)
(B) Stiffener plate bolt: 380 kg.cm (27 ft-lb, 37 N.m)
(C) Starter bolt: 400 kg.cm (29 ft.lb, 39 N.m)





6. -2 (22R-E)
INSTALL TRANSMISSION BOLTS AND STIFFENER BOLTS

Torque:
(A) Transmission bolt: 730 kg.cm (53 ft.lb, 72 N.m)
(B) Stiffener plate bolt: 380 kg.cm (27 ft.lb, 37 N.m)
(C) Starter bolt: 400 kg.cm (29 ft.lb, 39 N.m)





7. INSTALL NO.2 FRAME CROSSMEMBER
- Raise the transmission slightly with a jack.
- Install the No.2 frame crossmember to the side frame with the bolts.

Torque the bolts:

Torque: 970 kgf.cm (70 ft.lb, 95 N.m)

- Lower the transmission and transfer.
- Install the four mounting bolts to the engine rear mounting.
- Torque the bolts.

Torque: 130 kg-cm (9 ft.lb, 13 N.m)





8. INSTALL STABILIZER BRACKET SET BOLTS

Torque: 300 kg.cm (22 ft.lb, 29 N.m)

9. (22R-E)
REMOVE PIECE OF WOOD FROM FRONT AXLE
10. (3VZ-E)
INSTALL THE FRONT DIFFERENTIAL ASSEMBLY
- Install and torque the three bolts.

Torque:
Differential carrier cover to frame: 1,500 kg-cm (108 ft.lb, 147 N.m)
Others: 1,700 kg-cm (123 ft.lb, 167 N.m)





11. -1(3VZ-E)
INSTALL EXHAUST PIPE, BRACKET AND CLAMP
- Install exhaust pipe to the manifold.

Torque: 630 kg.cm (46 ft.lb, 62 N.m)

- Install exhaust pipe bracket to the clutch housing.

Torque: 400 kgf.cm (29 ft.lb, 39 N.m)

- Install exhaust pipe clamp.





- Connect the exhaust pipe to the catalytic converter front side, and torque the bolts.

Torque: 400 kg.cm (29 ft.lb, 39 N.m)





11. -2(22R-E)
INSTALL EXHAUST PIPE, BRACKET AND CLAMP
- Install the exhaust pipe to the manifold.

Torque: 630 kg.cm (46 ft.lb, 62 N.m)

- Install the pipe bracket to the clutch housing.
- Torque the bolts.

Torque:
Upper: 195 kg.cm (14 ft.lb, 19 N.m)
Lower: 700 kg.cm (51 ft.lb, 69 N.m)

- Install the exhaust pipe clamp.





12. -1 (3VZ-E)
INSTALL CLUTCH RELEASE CYLINDER
- Install clutch release cylinder and torque the two bolts.

Torque: 120 kg.cm (9 ft.lb, 12 N.m)





12. -2(22R-E)
INSTALL STARTER MOUNTING BOLTS, CLUTCH RELEASE CYLINDER AND TUBE BRACKET
- Install tube bracket and torque the starter lower mounting bolt and nut.

Torque: 400 kg.cm (29 ft-lb, 39 N.m)

- Install clutch release cylinder and torque the two bolts.

Torque: 120 kg.cm (9 ft-lb, 12 N.m)





13. (R150F, G58)
INSTALL PROPELLER SHAFT DUST COVER SUBASSEMBLY
- Install the cover.
- Install and torque the three bolts.

Torque:
A-bolt: 370 kg.cm (27 ft-lb, 36 N.m)
B-bolt: 230 kg.cm (17 ft-lb, 23 N.m)

14. CONNECT SPEEDOMETER CABLE, BACK-UP LIGHT SWITCH CONNECTOR AND TRANSFER INDICATOR SWITCH CONNECTOR
15. CONNECT PROPELLER SHAFT








16. FILL TRANSMISSION AND TRANSFER WITH OIL
17. LOWER VEHICLE





18. -1(R15OF, G58)
INSTALL TRANSFER SHIFT LEVER
- Apply MP grease to the transfer shift lever.
- Install the shift lever as shown.
- Using pliers, install snap ring.





18. -2(W56)
INSTALL TRANSFER SHIFT LEVER
- Apply MP grease to the transfer shift lever.
- Using pliers, install the shift lever and snap ring.





19. INSTALL TRANSMISSION SHIFT LEVER
- Apply MP grease to the transmission shift lever.
- Align the groove of the shift lever cap and the pin part of the case cover.
- Cover the shift lever cap with a cloth.
- Then, pressing down on the shift lever cap, rotate it clockwise to install.





20. (3VZ-E)
INSTALL HEATER HOSE CLAMP
- Move the clamp to correct position.
- Torque the clamp bolt.





21. INSTALL FAN SHROUD SET BOLTS
- Install and torque the four bolts.
22. CONNECT BATTERY CABLE TO NEGATIVE TERMINAL
23. PERFORM ROAD TEST
- Check for abnormal noise and smooth operation.