Installation

INSTALLATION
1. Apply a thin coat of molybdenum disulfide grease to the top gear shaft spline.
2. Slowly operate the transmission jack until the front of transmission is aligned with the rear of the engine. The slope of the engine and the transmission must be the same.





3. Align the top gear shaft spline with the clutch driven plate spline.





4. Install the transmission to the engine. Tighten the transmission nuts and bolts.
5. Apply a force of 59 - 78 N (13.2 - 17.6 lbs.) to the tip of the shift fork in the direction of the transmission to engage the clutch pressure plate and release bearing.





NOTE:
A clicking sound is heard when the release bearing and the tip of the diaphragm spring engage each other.
Check to see if they are securely engaged by pushing the tip of the shift fork toward the engine while applying a force of about 25 Nm (5.5 lbs.). If the shift fork will not move, then they are securely engaged.

6. Install three flywheel under cover.
7. Install the engine rear mount and tighten the fixing bolts specified torque.

Torque: 41 Nm (30 ft. lbs.)

8. Install the harness heat protector.
9. Install the right front exhaust pipes and catalytic converter assembly.

Torque:
Exh. pipe to exh. manifold: 67 Nm (49 ft. lbs.)
Exh. pipe flange bolt: 43 Nm (32 ft. lbs.)

10. Connect four oxygen sensor connectors to the transmission harness.
11. Install the third crossmember and tighten the fixing bolts specified torque.

Torque: 50 Nm (37 ft. lbs.)

12. Tighten the engine rear mount nuts specified torque.

Torque: 50 Nm (37 ft.lbs)

13. Remove the transmission jack.
14. Apply the grease to top hole portion of the shift fork.





15. Install the slave cylinder and tighten the fixing bolts specified torque.

Torque: 43 Nm (32 ft. lbs.)

Install the clutch dust cover to the clutch housing and tighten the fixing bolts specified torque.

Torque: 6 Nm (16 ft. lbs.)

16. Install the slave cylinder heat protector to the slave cylinder.





17. Install harness heat protector.





18. Install four fuel pipe bracket.





19. Install bracket and two transmission harness clamps to the transmission case.





20. Connect the speed sensor harness connector.





21. Connect the reverse lamp switch, 4WD indicator switch, 1-2 and 3-4 indicator switch harness connectors.
22. Install the front propeller shaft and tighten the fixing bolts and nuts specified torque.

Torque: 63 Nm (46 ft. lbs.)

23. Install the rear propeller shaft and tighten the fixing bolts and nuts specified torque.

Torque: 63 Nm (46 ft. lbs.)

24. Install transfer protector and tighten the fixing bolts specified torque.

Torque: 37 Nm (27 ft. lbs.)






25. Install the transmission control lever and transfer control lever.
26. Install the grommet assembly.
27. Install the front console assembly.
28. Install the gear control lever knob.
29. Connect battery ground cable.
30. Install engine hood.