Transmission Installation
Manual Transmission AssemblyINSTALLATION
1. Replace the differential side oil seal with a new one. (TURBO model)
NOTE: It is not necessary to replace the oil seal if a new one installed.
2. Install the rear cushion rubber to transmission assembly.
Tightening torque: 35 Nm (3.57 kgf-cm, 25.8 ft. lbs.)
3. Install the clutch release lever and bearing onto transmission. (Turbo model)
4. Install the transmission onto engine.
1. Gradually raise the transmission with transmission jack.
2. Engage them at splines.
NOTE: Be careful not to strike the main shaft against clutch cover.
5. While releasing turn buckle of engine support assembly ,raise upward transmission jack, and then return tilt of engine and transmission.
ST 41099AA000 ENGINE SUPPORT ASSY
6. Install the transmission rear crossmember. Tightening torque:
T1: 70 Nm (7.1 kgf-cm, 51 ft. lbs.)
T2: 140 Nm (14.3 kgf-cm, 103 ft. lbs.)
T3: 35 Nm (3.6 kgf-cm, 25.9 ft. lbs.)
7. Take off the transmission jack.
8. Tighten the nuts which hold the lower side of transmission to engine.
Tightening torque: 50 Nm (5.1 kgf-cm, 36.9 ft. lbs.)
9. Connect the engine and transmission.
1. Install the starter.
2. Tighten the bolt which holds right upper side of transmission to engine.
Tightening torque: 50 Nm (5.1 kgf-cm, 36.9 ft. lbs.)
10. Remove the ST.
11. Install the pitching stopper.
Tightening torque:
T1: 50 Nm (5.1 kgf-cm, 37 ft. lbs.)
T2: 58 Nm (5.9 kgf-cm, 43 ft. lbs.)
12. Lift-up the vehicle.
13. Drive the spring pin into chamfered hole of drive shaft. (Non-TURBO model)
NOTE: Always use a new spring pin.
14. Replace the circlip with a new one, and insert the front drive shaft to transmission. (TURBO model)
ST 28399SA010 FRONT DRIVE SHAFT OIL SEAL PROTECTOR
15. Install the ball joints of lower arm into knuckle arm of housing, and tighten the installing bolts.
Tightening torque: 49 Nm (5.0 kgf-cm, 36 ft. lbs.)
16. Install the stabilizer link from transverse link.
Tightening torque: 30 Nm (3.1 kgf-cm 22.1 ft. lbs.)
17. Install the gear shift rod and stay.
1. Install the gear shift rod onto transmission.
2. Install the stay onto transmission.
18. Install the propeller shaft.
19. Install the heat shield cover. (If equipped)
20. Install the hanger bracket on right side of transmission.
21. Install the rear exhaust pipe and muffler.
22. Install the front exhaust pipe and center exhaust pipe. (Non-TURBO model)
23. Install the center exhaust pipe. (TURBO model)
24. Install the under cover.
25. Push the clutch release lever to fit the bearing into clutch cover. (TURBO model)
26. Install the operating cylinder.
Tightening torque: 37 Nm (3.8 kgf-cm, 27.5 ft. lbs.)
^ Non-TURBO MODEL
^ TURBO MODEL
27. Connect the following connectors:
1. Transmission ground cable
Tightening torque: 13 Nm (1.3 kgf-cm, 9.4 ft. lbs.)
2. Vehicle speed sensor connector
3. Neutral position switch connector
4. Back-up light switch connector
28. Install the air cleaner case stay. (Non-TURBO model)
Tightening torque: 16 Nm (1.6 kgf-cm, 11.6 ft. lbs.)
29. Install the air cleaner case or the air intake chamber and duct. (Non-TURBO model)
30. Install the intercooler. (TURBO model)