Installation

GENERAL PRECAUTION
1. Remove or install transmission in an area where chain hoists, lifting devices, etc. are available for ready use.
2. Be sure not to damage coated surfaces of body panels with tools or stain seats and windows with coolant or oil. Place a cover over fenders, as required, for protection.
3. Prior to starting work, prepare the following: Service tools, clean cloth, containers to catch coolant and oil, wire ropes, chain hoist, transmission jacks, etc.
4. Lift-up or lower the vehicle when necessary. Make sure to support the correct positions.

INSTALLATION





1. Install ST to torque converter clutch case. (AT vehicles) ST 498277200 STOPPER SET





2. Install transmission to engine.
1. Gradually raise transmission with transmission jack.
2. Engage them at splines.

CAUTION: Be careful not to strike mainshaft against clutch cover. (MT vehicles)

3. Install transmission rear crossmember.





- MT vehicles
Tightening torque:
T1: 69 ± 15 Nm (7.0 ± 1.5 kg-m, 51 ± 11 ft. lbs.)
T2: 137 ± 20 Nm (14 ± 2 kg-m, 101 ± 14 ft. lbs.)





- AT vehicles
Tightening torque:
T1: 34 ± 10 Nm (3.5 ± 1.0 kg-m, 25.3 ± 7.2 ft. lbs.)
T2: 69 ± 15 Nm (7.0 ± 1.5 kg-m, 51 ± 11 ft. lbs.)
4. Take off transmission jack.





5. Tighten nuts which hold lower side of transmission to engine.
Tightening torque: 50 ± 4 Nm (5.1 ± 0.4 kg-m, 36.9 ± 2.9 ft. lbs.)





6. Tighten bolt which holds right upper side of transmission to engine.
Tightening torque: 50 ± 4 Nm (5.1 ± 0.4 kg-m, 36.9 ± 2.9 ft. lbs.)





7. Install torque converter to drive plate. (AT vehicles)
1. Tighten bolts which hold torque converter to drive plate.
2. Tighten other bolts while rotating the engine by using ST.
2200 cc vehicles: ST 499977300 CRANK PULLEY WRENCH
2500 cc vehicles: ST 499977100 CRANK PULLEY WRENCH

CAUTION: Be careful not to drop bolts into torque converter housing.

Tightening torque: 25 ± 2 Nm (2.5 ± 0.2 kg-m, 18.1 ± 1.4 ft. lbs.)
3. Clog plug onto service hole.





8. Install operating cylinder. (2500 cc MT vehicle)
Tightening torque: 37 ± 3 Nm (3.8 ± 0.3 kg-m, 27.5 ± 2.2 ft. lbs.)





9. Remove special tools.





10. Install pitching stopper.
Tightening torque:
T1: 57 ± 10 Nm (5.8 ± 1.0 kg-m, 42 ± 7 ft. lbs.)
T2: 49 ± 5 Nm (5.0 ± 0.5 kg-m, 36.2 ± 3.6 ft. lbs.)
11. Install front drive shafts into transmission.
1. Lift-up the vehicle.
2. Install front drive shaft into transmission.





3. Drive spring pin into chamfered hole of drive shaft.

CAUTION: Always use a new spring pin.





4. Install ball joints of lower arm into knuckle arm of housing, and tighten installing bolts.
Tightening torque: 49 ± 10 Nm (5.0 ± 1.0 kg-m, 36 ± 7 ft. lbs.)





12. Install stabilizer clamps onto front crossmember.
Tightening torque: 25 ± 4 Nm (2.5 ± 0.4 kg-m, 18.1 ± 2.9 ft. lbs.)





13. Install gear shift rod and stay. (MT vehicles)
1. Install gear shift rod onto transmission.
2. Install stay onto transmission.
Tightening torque: 18.5 ± 5 Nm (1.8 ± 0.5 kg-m, 13.6 ± 3.6 ft. lbs.)
14. Install shift selector cable onto selector lever. (AT vehicles)
1. Install selector cable to range select lever.





2. Install cable clamp to plate assembly.





3. Install snap pin to range select lever.





15. Install ATF level gauge guide, and ATF cooler hoses onto pipe. (AT vehicles)
16. Install propeller shaft.
1. Install propeller shaft into transmission.





2. Tighten bolts which install propeller shaft onto companion flange of rear differential.
Tightening torque:
T: 31 ± 8 Nm (3.2 ± 0.8 kg-m, 23.1 ± 5.8 ft. lbs.)





3. Install center bearing bracket on body.
Tightening torque:
T: 52 ± 5 Nm (5.3 ± 0.5 kg-m, 38.3 ± 3.6 ft. lbs.)
17. Install exhaust system.





1. Install heat shield cover.





2. Install rear exhaust pipe to muffler.
Tightening torque: 48 ± 5 Nm (4.9 ± 0.5 kg-m, 35.4 ± 3.6 ft. lbs.)





3. Install hanger bracket on right side of transmission.





4. Install front exhaust pipe onto engine.
Tightening torque: 30 ± 5 Nm (3.1 ± 0.5 kg-m. 22.4 ± 3.6 ft. lbs.)





5. Install center exhaust pipe to rear exhaust pipe.
Tightening torque: 18 ± 5 Nm (1.8 ± 0.5 kg-m, 13.0 ± 3.6 ft. lbs.)





6. Tighten bolt which installs center exhaust pipe to hanger bracket.
Tightening torque: 35 ± 5 Nm (3.6 ± 0.5 kg-m, 26.0 ± 3.6 ft. lbs.)





7. Connect connector to rear oxygen sensor.





18. Install ATF level gauge. (AT vehicles)
19. Connect the following connectors.





1. Transmission harness connectors
2. Transmission ground terminal





3. Front oxygen sensor connector





4. Vehicle speed sensor connector (MT vehicles)





5. Neutral position and back-up light switch connector (MT vehicles)





20. Install starter.
1. Install starter onto transmission case, and connect connectors and terminals.
2. Tighten bolt and nut which install starter onto transmission.
Tightening torque: 50 ± 4 Nm (5.1 ± 0.4 kg-m, 36.9 ± 2.9 ft. lbs.)
21. Install air cleaner case stay.

MT Vehicles:

- MT vehicles

AT Vehicles:

- AT vehicles
22. Install air intake duct with air cleaner case.
23. Connect battery ground cable.
24. Fill ATF up to the middle of the "COLD" side on level gauge by using the gauge hole. (AT vehicles)
Recommended fluid:
Dexron IIE or Dexron III type automatic transmission fluid
Fluid Capacity:
2200 cc
8.9 - 9.2 qt (8.4 - 8.7L)
2500 cc
9.8 - 10.1 qt (9.3 - 9.6L)
25. Check selector lever operation. (AT vehicles)
26. Take off vehicle from lift arms.
27. Run the vehicle until ATF temperature rises from 60 to 80°C (140 to 176°F) and check the ATF level of the "HOT" side on the level gauge. (AT vehicles)
28. Check the vehicle on road tester. (AT vehicles)