Transmission Installation

Manual Transmission Assembly

INSTALLATION
1) Replace the differential side retainer oil seal with a new part.
ST 18675AA000 DIFFERENTIAL SIDE OIL SEAL INSTALLER

NOTE: Be sure to replace the differential side retainer oil seal after the removing the front drive shaft.





2) Install the transmission cushion rubber to the transmission assembly.
Tightening torque: 35 N-m (3.6 kgf-m, 25.8 ft-lb)
3) Install the transmission onto the engine.
1) Gradually raise the transmission with the transmission jack.
2) Engage at the spline section.

NOTE: Be careful not to hit the main shaft against the clutch cover.

4) Loosen the turnbuckle of the ST while raising the transmission jack to return the engine to its original position.
5) Install the front crossmember and rear cross-member.
Tightening torque:
T1: 70 N-m (7.1 kgf-m, 51.6 ft-lb)
T2: 140 N-m (14.3 kgf-m, 103.3 ft-lb)





6) Take out the transmission jack.
7) Tighten the nuts and bolts which holds the lower side of the transmission to the engine.
Tightening torque: 50 N-m (5.1 kgf-m, 36.9 ft-lb)





8) Connect the engine and transmission.
1) Install the starter.
2) Tighten the bolts which holds the upper side of the transmission to the engine.
Tightening torque: 50 N-m (5.1 kgf-m, 36.9 ft-lb)





9) Remove the ST.





10) Install the pitching stopper.
Tightening torque:
T1: 50 N-m (5.1 kgf-m, 36.9 ft-lb)
T2: 58 N-m (5.9 kgf-m, 42.8 ft-lb)





11) Lift up the vehicle.
12) Install the front drive shaft into the transmission.
ST 28399SA010 FRONT DRIVE SHAFT OIL SEAL PROTECTOR
13) Insert the ball joints of the transverse link into the housing, then tighten the installing bolts.
Tightening torque: 50 N-m (5.1 kgf-m, 36.9 ft-lb)





14) Attach the stabilizer link to the transverse link.
Tightening torque: 45 N-m (4.6 kgf-m, 33.2 ft-lb)





15) Attach the gear shift rod and stay.
1) Attach the gear shift rod to the transmission.
Tightening torque: 12 N-m (1.2 kgf-m, 8.9 ft-lb)





2) Attach the stay to the transmission.
Tightening torque: 18 N-m (1.8 kgf-m, 13.3 ft-lb)
16) Install the propeller shaft.
17) Install the hanger bracket on the right side of the transmission.





18) Install the rear exhaust pipe and muffler.
19) Install the front exhaust pipe and the center exhaust pipe. (Non-turbo model)
20) Install the center exhaust pipe. (Turbo model)
21) Install the under cover.
22) Install the operating cylinder.
Tightening torque: 37 N-m (3.8 kgf-m, 27.5 ft-lb)





23) Connect the following connectors.
1) Transmission ground cable
Tightening torque: 13 N-m (1.3 kgf-m, 9.4 ft-lb)
2) Vehicle speed sensor connector
3) Neutral position switch connector
4) Back-up light switch connector
24) Install the air intake chamber stay.
25) Install the intake boot and air intake chamber.
26) Install the intercooler. (Turbo model)
27) Pour transmission gear oil through the gauge hole.
28) Connect the ground cable to the battery.