Manual Transmission Assembly
Manual Transmission AssemblyREMOVAL
1. Set vehicle on a lift.
2. Open front hood fully, and support with stay.
3. Disconnect battery ground cable.
4. Move shift lever to "N", and release the parking brake.
5. Remove air intake duct.
6. Remove air cleaner case.
MT Vehicles:
7. Remove air cleaner case stay.
8. Disconnect the following connectors.
1. Neutral position switch connector
2. Back-up light switch connector
3. Vehicle speed sensor
4. Transmission ground terminal
9. Remove starter.
10. Remove operating cylinder from transmission.
11. Remove pitching stopper.
12. Set ST.
ST 41099AA000 ENGINE SUPPORT ASSY
13. Remove bolt which holds right upper side of transmission to engine.
14. Remove under cover.
15. Remove front and center exhaust pipes.
16. Remove rear exhaust pipe and muffler.
17.5Remove heat shield cover.
18. Remove hanger bracket from right side of transmission.
19. Remove propeller shaft.
20. Remove gear shift rod and stay from transmission.
1. Disconnect stay from transmission.
2. Disconnect rod from transmission.
21. Disconnect stabilizer link from transverse link.
22. Remove bolt securing ball joint of transverse link to housing and separate ball joint and transverse link.
23. Remove spring pins and separate front drive shafts from each side of the transmission.
NOTE: Discard removing spring pin. Replace with a new one.
24. Remove nuts which hold lower side of transmission to engine.
25. Place transmission jack under transmission.
CAUTION:
^ Always support transmission case with a transmission jack.
^ Fix transmission with a band etc.
26. Remove transmission rear crossmember from vehicle.
27. Move transmission jack toward rear until main shaft is withdrawn from clutch cover.
28. Separate transmission assembly and rear cushion rubber.
INSTALLATION
1. Install rear cushion rubber to transmission assembly.
Tightening torque: 35 Nm (3.6 kgf-m, 26 ft. lbs.)
2. Install transmission onto engine.
1. Gradually raise transmission with transmission jack.
2. Engage them at splines.
NOTE: Be careful not to strike main shaft against clutch cover.
3. Install transmission rear crossmember.
Tightening torque:
T1: 75 Nm (7.6 kgf-m, 55 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-cm, 37 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, 37 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 shafts into transmission.
11. New drive spring pin into chamfered hole of drive shaft.
12. Install ball joints of lower arm into knuckle arm of housing, and tighten installing bolts.
Tightening torque: 50 Nm (5.1 kgf-m, 37 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 front, center, rear, exhaust pipe and muffler.
20. Install under cover.
21. Install operating cylinder.
Tightening torque: 37 Nm (3.8 kgf-m, 27.5 ft. lbs.)
22. 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
23. Install air cleaner case stay.
Tightening torque: 16 Nm (1.6 kgf-m, 11.6 ft. lbs.)
24. Install air cleaner case and air intake duct.
25. Connect battery ground cable.
26. Pour gear oil and check the oil level.
27. Take off vehicle from lift arms.