Transmission Installation

Manual Transmission Installation




1. Be sure that the two dowel pins are installed in the transmission housing.
2. Apply Super High Temp Urea Grease (P/N 08798-9002) on the release fork (A) and the release bearing (B) in the shaded areas. Install the release fork and release bearing.




3. With the transmission attached to the special tool and the transmission jack rotated down to a 45 degree angle, raise the transmission up to engine level. Then rotate the rear of the transmission to align the dowel pins.




4. Install the transmission mounting bolts.




5. Install the clutch cover.




6. Install the front engine mount bracket.




7. Remove the special tool, then install the transmission side mount (A) to the transmission, then loosely tighten the three bolts (B).







8. Install the front beam (A) by aligning both reference marks (B) on both rear beams (C), and tighten the bolts (D) to the specified torque.
9. Install the transmission lower mount nuts (E) and tighten them tot he specified torque.
10. Connect the vacuum tube (F), and install the power steering fluid tube (G) on its clamps.





11. Tighten the three bolts on the transmission side mount.




12. Install the radius rods (A) on each lower arm.
13. Install the intermediate shaft.
14. Install the driveshafts.
15. Install the damper fork (B), then install the ball joints on each lower arm (C) with castle nuts (D) and new cotter pins (E).




16. Install the splash shield.




17. Install the two upper transmission mounting bolts.
18. Remove the engine hanger and special tool from engine.




19. Apply Super High Temp Urea Grease (P/N 08798-9002) to the end of the slave cylinder rod. Install the slave cylinder. Be careful not to bend the clutch line.




20. Install the cable bracket (A), cables (B), and harness bracket (C).




21. Install the ground cable (A), and CKP sensor B (B), then connect the CKP sensor B connector (C).




22. Connect the harness clips (A) and ground cable (B).




23. Install the starter motor (A), then connect the starter cable (B) and ground cable (C).





24. Connect the countershaft speed sensor connector (A) and mainshaft speed sensor connector (B).




25. Install the front engine mount nut and front engine lock damper bracket bolts.




26. Connect the back-up light switch connector (A) and reverse lockout solenoid (B).




27. Install the battery tray.
28. Install the battery.




29. Install the engine cover.
30. Install the intake air duct.
31. Connect the positive (+) cable first, then the negative (-) to the battery.
32. Refill the transmission fluid.
33. Test-drive the vehicle.
34. Check the clutch operation.
35. Check the front wheel alignment.
36. Enter the anti-theft code for the radio and navigation system, then enter the customer's radio station presets.




37. Loosen the front engine mount nut after the road test, then retighten the nut to the specified torque.