Removal and Installation
A: REMOVAL1. Set vehicle on a lift.
2. Open front hood fully, and support with stay.
3. Disconnect battery ground cable.
4. Move gear shift lever to "N", and release the parking brake.
5. Remove air intake duct and cleaner case.
MT Vehicles:
6. Remove air cleaner case stay.
7. Disconnect the following connectors.
1. Neutral position switch connector
2. Back-up light switch connector
3. Vehicle speed sensor
4. Transmission ground cable.
8. Remove starter.
9. Remove operating cylinder from transmission.
10. Remove pitching stopper.
11. Set ST.
NOTE: Part No. 41099AA010 is also available.
ST 41099M020 ENGINE SUPPORT ASSY
12. Remove bolt which holds right upper side of transmission to engine.
13. Remove front and center exhaust pipes.
14. Remove rear exhaust pipe and muffler.
CAUTION: When removing exhaust pipes, be careful each exhaust pipe does not drop out.
15. Remove heat shield cover.
16. Remove hanger bracket from right side of transmission.
17. Remove propeller shaft.
18. Remove gear shift rod and stay from transmission.
1. Disconnect stay from transmission.
2. Disconnect rod from transmission.
19. Disconnect stabilizer link from transverse link.
20. Remove bolt securing ball joint of transverse link to housing.
21. Remove spring pins and separate front drive shafts from each side of the transmission.
CAUTION: Discard removing spring pin. Replace with a new one.
22. Remove nuts, which hold lower side of transmission to engine.
23. Place transmission jack under transmission.
CAUTION: Always support transmission case with a transmission jack.
24. Remove transmission rear crossmember from vehicle.
25. Remove transmission.
CAUTION: Move transmission jack toward rear until main shaft is withdrawn from clutch cover.
26. Separate transmission assembly and rear cushion rubber.
B: INSTALLATION
1. Install rear cushion rubber to transmission assembly.
Tightening torque: 34 Nm (3.5 kgf-m, 25.3 ft. lbs.)
2. Install transmission onto engine.
1. Gradually raise transmission with transmission jack.
2. Engage them at splines.
CAUTION: Be careful not to strike main shaft against clutch cover.
3. Install transmission rear crossmember.
Tightening torque:
T1: 70 Nm (7.1 kgf-m, 51 ft. lbs.)
T2: 140 Nm (14.3 kgf-m, 103 ft. lbs.)
4. Take off transmission jack.
5. Tighten nuts, which hold lower side of transmission to engine.
Tightening torque: 50 Nm (5.1 kgf-m, 36.9 ft. lbs.)
6. Connect engine and transmission.
1. Install starter.
2. Tighten bolt which holds right upper side of transmission to engine.
Tightening torque: 50 Nm (5.1 kgf-m, 36.9 ft. lbs.)
7. Remove ST.
8. Install pitching stopper.
Tightening torque:
T1: 50 Nm (5.1 kgf-m, 37 ft. lbs.)
T2: 58 Nm (5.9 kgf-m, 43 ft. lbs.)
9. Lift-up the vehicle.
10. Install front drive shaft into transmission.
11. Drive spring pin into chamfered hole of drive shaft.
CAUTION: Always use a new spring pin.
12. Install ball joints of lower arm into knuckle arm of housing, and tighten installing bolts.
Tightening torque: 49 Nm (5.0 kgf-m, 36 ft. lbs.)
13. Install stabilizer link from transverse link.
Tightening torque: 30 Nm (3.1 kgf-m, 22.1 ft. lbs.)
14. Connect rod to the joint.
Tightening torque: 18 Nm (1.8 kgf-m, 13.0 ft. lbs.)
15. Connect stay to transmission bracket.
Tightening torque: 18 Nm (1.8 kgf-m, 13.0 ft. lbs.)
16. Install propeller shaft.
17. Install heat shield cover.
18. Install hanger bracket on right side of transmission.
19. Install rear exhaust pipe and muffler.
20. Install front exhaust pipe and center exhaust pipe.
21. Install under cover.
22. Install operating cylinder.
Tightening torque: 37 Nm (3.8 kgf-m, 27.5 ft. lbs.)
23. Connect the following connectors.
1. Transmission ground terminal
Tightening torque: 13 Nm (1.3 kgf-m, 9.4 ft. lbs.)
2. Vehicle speed sensor connector
3. Neutral position switch connector
4. Back-up light switch connector
24. Install air cleaner case stay.
Tightening torque: 16 Nm (1.6 kgf-m, 11.6 ft. lbs.)
25. Install air cleaner case and intake duct. (Nonturbo model)
26. Connect battery ground cable.
27. Pour gear oil and check the oil level.
28. Take off vehicle from lift arms.