Transmission Replacement

Transmission Replacement

Removal Procedure

1. Remove the battery and battery tray. Refer to Battery Tray Replacement Service and Repair.

2. Without draining the coolant or removing the hoses, remove and position aside the radiator surge tank. Refer to Radiator Surge Tank Replacement Radiator Surge Tank Replacement.




3. Disconnect the shift lever and selector lever cable end (1) from the transmission shift lever and selector lever.

4. Pull the cable retainers (2) to release the shift lever and selector lever cable from the shift lever and selector lever cable bracket.

5. Disconnect the shift lever and selector lever cable from the shift lever and selector lever cable bracket.





Note: Before disconnecting the clutch actuator cylinder front pipe, remove the clutch/brake fluid from the reservoir tank.

6. Remove the clutch actuator cylinder front pipe retaining clip (1).

7. Disconnect the clutch actuator cylinder front pipe (2) from the clutch actuator cylinder pipe elbow.




8. Disconnect the electrical connector (1) from the backup lamp switch (2).




9. Disconnect the speedometer driven gear electrical connector (1).




10. Remove the upper transmission bolts (1).

11. Install the engine support fixture. Refer to Engine Support Fixture 1. Engine Support Fixture.

12. Drain the transmission fluid. Refer to Transmission Fluid Drain and Fill Transmission Fluid Drain and Fill.

13. Remove the front exhaust pipe. Refer to Exhaust Front Pipe Replacement (LUV,LUW) Service and Repair.




14. Remove the right front wheel drive shaft from the transmission. Refer to Front Wheel Drive Shaft Replacement Front Wheel Drive Shaft Replacement.

15. Remove the left front wheel drive shaft from the transmission. Refer to Front Wheel Drive Shaft Replacement Front Wheel Drive Shaft Replacement.




16. Remove the rear transmission mount (3). Refer to Transmission Rear Mount Replacement Transmission Rear Mount Replacement.

17. Remove the drivetrain and front suspension frame. Refer to Drivetrain and Front Suspension Frame Replacement .




18. Remove the left transmission mount (4). Refer to Transmission Mount Replacement - Left Side Transmission Mount Replacement - Left Side.

19. Remove the left transmission mount bracket. Refer to Transmission Mount Bracket Replacement - Left Side Transmission Mount Bracket Replacement - Left Side.

20. Use a transmission jack in order to support the transmission.




21. Remove the lower transmission bolt (3) and nut (4).

22. Remove the lower transmission bolts (1, 2)

23. Separate the transmission from the engine.

24. Lower the transmission with the transmission jack far enough to remove the transmission.

Installation Procedure

Warning

Use care when cleaning the clutch hub. The clutch hub may have sharp edges and can cause personal injury if contact is made. Wear protective gloves to avoid personal injury.

1. Clean the clutch hub and the input shaft from any debris and contaminates with a lint-free towel.





Caution:
Applying too much or the wrong type of grease on the transmission input shaft may cause damage, clutch slippage or failure. Always apply the correct type of grease. Never apply more grease than is necessary to coat the transmission input shaft with a very thin film of grease.

2. Use a clean flat brush (1) to apply very light coating of multi-purpose grease to input shaft until the metal is only shiny. No visible clumps of grease are permissible regardless of size. Smear away from the transmission in direction of the shown arrow.





Caution:
Ensure that no grease remains on the lead surface of the transmission input shaft. Clean the lead surface of the transmission input shaft prior to the assembly of the transmission to the engine. Failure to maintain a clean surface may cause clutch slippage or failure.

3. Clean the entire lead surface of the input shaft with a NEW, lint-free towel (1).

4. Raise the transmission with the transmission jack and position the transmission to the engine.





Caution: Refer to Fastener Caution Fastener Caution.

5. Install the lower transmission bolts (1) and tighten to 60 Nm (44 lb ft).

6. Install the lower transmission bolts (2) and tighten to 40 Nm (32 lb ft).

7. Install the lower transmission bolt (3) and nut (4) and tighten to 40 Nm (32 lb ft).

8. Remove the transmission jack.

9. Install the left transmission mount bracket. Refer to Transmission Mount Bracket Replacement - Left Side Transmission Mount Bracket Replacement - Left Side.




10. Install the left transmission mount (4). Refer to Transmission Mount Replacement - Left Side Transmission Mount Replacement - Left Side.

11. Install the drivetrain and front suspension frame. Refer to Drivetrain and Front Suspension Frame Replacement .




12. Install the rear transmission mount (3). Refer to Transmission Rear Mount Replacement Transmission Rear Mount Replacement.




13. Install the left front wheel drive shaft to the transmission. Refer to Front Wheel Drive Shaft Replacement Front Wheel Drive Shaft Replacement.

14. Install the right front wheel drive shaft to the transmission. Refer to Front Wheel Drive Shaft Replacement Front Wheel Drive Shaft Replacement.

15. Install the front exhaust pipe. Refer to Exhaust Front Pipe Replacement (LUV,LUW) Service and Repair.




16. Remove the engine support fixture. Refer to Engine Support Fixture 1. Engine Support Fixture.

17. Install the upper transmission to engine bolts (1) and tighten to 60 Nm (44 lb ft).




18. Connect the speedometer driven gear electrical connector (1).




19. Connect the electrical connector (1) to the backup lamp switch (2).

20. Connect the wiring harness clamp to the transmission.





Note: The clutch actuator cylinder front pipe must engage noticeably.

21. Connect the clutch actuator cylinder front pipe (2) to the clutch actuator cylinder pipe elbow.

22. Lock the clutch actuator cylinder front pipe retaining clip (1).




23. Connect the shift lever and selector lever cable ends (1) to the transmission shift lever and selector lever.

24. Install the shift lever and the selector lever cable (3) to the shift lever and the selector lever cable bracket.

25. Adjust the shift lever and selector lever cables. Refer to Manual Transmission Shift Lever and Selector Lever Cable Adjustment Manual Transmission Shift Lever and Selector Lever Cable Adjustment.

26. Fill the transmission with fluid. Refer to Transmission Fluid Drain and Fill Transmission Fluid Drain and Fill.

27. Install the radiator surge tank. Refer to Radiator Surge Tank Replacement Radiator Surge Tank Replacement.

28. Install the battery and battery tray. Refer to Battery Tray Replacement Service and Repair.

29. Bleed the clutch hydraulic system. Refer to Hydraulic Clutch System Bleeding Service and Repair.

30. Road test the vehicle.