Transmission Installation
Manual Transmission AssemblyINSTALLATION
1) Set the release fork, release bearing and release shaft to transmission.
2) Install the crossmember to transmission.
3) Install the transmission.
NOTE:
^ Make sure the main shaft spline part is inserted completely.
^ Make sure the rear side of engine is lowered.
4) Move the transmission to the right side, then install the joint COMPL bolt, stay bolt and reverse check cable.
5) Install the front crossmember and rear crossmember.
NOTE:
Rotate the turn buckle of ST (ENGINE SUPPORT ASSY) and lift up the rear side of engine to facilitate installation.
6) Lower the vehicle and install the fixing bolt.
7) Make sure the release bearing is installed completely.
NOTE:
^ Push the release fork to operating cylinder side until you hear a "click" sound. Pull the release fork to engine side. Setting is completed if the release fork does not contact the case.
^ Make sure the boot cover is firmly set.
8) Install the pitching stopper bracket.
Tightening torque:
41 Nm (4.2 kgf-m, 30.2 ft. lbs.)
9) Install the pitching stopper.
10) Install the throttle body.
11) Install the operating cylinder.
Tightening torque:
41 Nm (4.2 kgf-m, 30.2 ft. lbs.)
NOTE:
Check that the clutch hose is routed properly.
12) Install the starter assembly.
Tightening torque:
50 Nm (5.1 kgf-m, 36.9 ft. lbs.)
13) Install the transmission and body ground cable.
14) Connect the connector located on the upper side of transmission.
15) Replace the front differential side retainer oil seal.
(1) Remove the oil seal by using flat tip screwdriver and etc.
(2) Fit a new oil seal using ST.
ST 18675AA000 DIFFERENTIAL SIDE OIL SEAL INSTALLER
NOTE:
^ Apply oil to the oil seal lips.
^ Always replace the differential side oil seal after extracting front drive shaft from the transmission.
16) Apply grease to the oil seal lips.
17) Set the ST to the differential side retainer.
ST 28399SA010 OIL SEAL PROTECTOR
18) Install the front drive shaft into transmission.
NOTE:
Replace the circlip of drive shaft with a new one.
19) Install the front drive shaft into transmission, remove the ST and insert the drive shaft securely.
ST 28399SA010 OIL SEAL PROTECTOR
20) Install the ball joint of transverse link to housing.
21) Install the stabilizer nut.
Tightening torque:
45 Nm (4.6 kgf-m, 33.2 ft. lbs.)
NOTE:
Use a new self-locking nut.
22) Install the propeller shaft.
23) Install the center exhaust pipe.
24) Install the rear exhaust pipe and muffler.
25) Install the universal joint.
26) Install the under cover.
27) Install the intercooler assembly.
28) Connect the battery ground cable to battery.