Transmission Replacement

Transmission Replacement

Special Tools

EN-45059 - Angle Meter

For equivalent regional tools, refer to Special Tools Tools and Equipment.

Removal Procedure

1. Remove the battery tray. Refer to Battery Tray Replacement Battery Tray Replacement.

2. Remove the transmission shift lever cable from the transmission. Refer to Manual Transmission Shift Lever and Selector Lever Cable Replacement Manual Transmission Shift Lever and Selector Lever Cable Replacement.




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

4. Remove the vehicle speed sensor. Refer to Vehicle Speed Sensor Replacement Service and Repair.





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

5. Remove the clutch actuator cylinder front pipe retainer (1).

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




7. Unclip the wiring harness from the transmission.

8. Remove the 2 upper transmission bolts from the engine (1).

9. Remove the drivetrain and front suspension frame. Refer to Drivetrain and Front Suspension Frame Replacement Service and Repair.




10. Remove the transmission front mount from the transmission (2).

11. Remove the 2 transmission front mount bolts (1).




12. Remove the transmission mount bracket bolts (1) and the rear transmission mount bracket (2).

13. Drain the transmission. Refer to Transmission Fluid Drain and Fill Transmission Fluid Drain and Fill.

14. Disconnect the left front wheel drive shaft from the transmission. Refer to Front Wheel Drive Shaft Replacement - Left Side Front Wheel Drive Shaft Replacement - Left Side.

15. Disconnect the right front wheel drive shaft from the transmission. Refer to Front Wheel Drive Shaft Replacement - Right Side Front Wheel Drive Shaft Replacement - Right Side.

16. Lower the vehicle.

17. Install the engine support fixture. Refer to Engine Support Fixture Engine Support Fixture.




18. Remove and DISCARD the transmission mount bolts (1) from the transmission mount bracket.

19. Lower the engine and the transmission on the left hand side with the engine support fixture.




20. Remove the transmission mount bracket - left side from the transmission (2).

21. Remove the 3 transmission mount bracket bolts (1).

22. Raise the vehicle.




23. Using suitable straps or chains, secure the transmission to a suitable transmission jack.

24. Remove the 4 transmission bolts (1)

25. Re-cut the transmission drain hole thread.

Caution: Refer to Fastener Caution Fastener Caution.

Note: Service may offer plugs that are not microencapsulated. If this is the case apply thread lock agent to the plug.

If fastener is microencapsulated, install a NEW transmission fluid drain plug. DO NOT reuse the old plug.

26. Install a NEW oil drain plug and tighten to 20 Nm (15 lb ft).




27. Remove the remaining lower transmission bolts (1).

28. Separate the transmission from the engine.

29. Lower the transmission from the vehicle.

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. For the approved type of grease, refer to Adhesives, Fluids, Lubricants, and Sealers .

3. Use a clean flat brush (1) to apply very light coating of grease to input shaft until the metal is only shiny. No visible clumps of grease are permissible regardless of size. Smear away form 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.

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

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





Caution: Refer to Fastener Caution Fastener Caution.

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

7. Remove the transmission jack.




8. Install the 4 transmission lower bolts (1) and tighten to 60 Nm (44 lb ft).

9. Lower the vehicle.




10. Install the transmission mount bracket - left side. Install the 3 transmission mount bracket bolts (1) and tighten to 100 Nm (74 lb ft).

11. Raise the engine and the transmission on the left hand side with the engine support fixture.




12. Install the 3 NEW transmission mount bolts (1) but do not tighten yet.

13. Raise the vehicle.

14. Install the front wheel drive intermediate shaft. Refer to Front Wheel Drive Intermediate Shaft Replacement Front Wheel Drive Intermediate Shaft Replacement.

15. Install the left front wheel drive shaft to the transmission. Refer to Front Wheel Drive Shaft Replacement - Left Side Front Wheel Drive Shaft Replacement - Left Side.




16. Install the transmission mount bracket - rear (2) and tighten the bolts (1) to 100 Nm (74 lb ft).




17. Install the transmission front mount to the transmission (2).

18. Install the 2 transmission front mount bolts (1) and tighten to 100 Nm (74 lb ft).

19. Install the drivetrain and the front suspension frame. Refer to Drivetrain and Front Suspension Frame Replacement Service and Repair.

20. Lower the vehicle.




21. Tighten the NEW transmission mount bolts left side (1) a first pass to 50 Nm (37 lb ft).

Caution: Refer to Torque-to-Yield Fastener Caution Torque-to-Yield Fastener Caution.

22. Tighten the NEW transmission mount bolts a final pass to an additional 60 - 75 degrees, using the EN-45059 - meter.

23. Remove the engine support fixture. Refer to Engine Support Fixture Engine Support Fixture.




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




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

26. Install the clutch actuator cylinder front pipe retainer (1) to the clutch actuator cylinder pipe elbow.

27. Install the vehicle speed sensor. Refer to Vehicle Speed Sensor Replacement Service and Repair.




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

29. Install the transmission shift lever cable to the transmission. Refer to Manual Transmission Shift Lever and Selector Lever Cable Replacement Manual Transmission Shift Lever and Selector Lever Cable Replacement.

30. 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.

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

32. Fill the transmission. Refer to Transmission Fluid Drain and Fill Transmission Fluid Drain and Fill.

33. Install the battery tray. Refer to Battery Tray Replacement Battery Tray Replacement.

34. Road test the vehicle.