Transmission Installation
Manual Transmission AssemblyINSTALLATION
1) Replace the differential side retainer oil seal.
NOTE:
Be sure to replace the differential side retainer oil seal after removing the front drive shaft.
ST 18675AA000 DIFFERENTIAL SIDE OIL SEAL INSTALLER
2) Tap the transmission hanger in the rear side of transmission with a rubber hammer to bend it until it is in close contact with the transmission case.
CAUTION:
Do not apply excessive load or impact to the transmission case.
3) Install the transmission cushion rubber to the transmission assembly, and tighten bolt (A)
4) Install the transmission cushion rubber to the center crossmember, and tighten the nut (B).
Tightening torque:
Bolt (A)
35 Nm (3.6 kgf-m, 25.8 ft-lb)
Nut (B)
35 Nm (3.6 kgf-m, 25.8 ft-lb)
5) Install the transmission onto the engine.
(1) Lift up the transmission gradually using a transmission jack.
(2) Engage at the spline section.
NOTE:
Be careful not to hit the main shaft against the clutch cover.
6) While raising the transmission jack, loosen the turnbuckle of the ST, and set the engine unit to the original position.
7) Install the front crossmember and rear crossmember.
Tightening torque:
T1: 70 Nm (7.1 kgf-m, 51.6 ft-lb)
T2: 140 Nm (14.3 kgf-m, 103.3 ft-lb)
8) Take out the transmission jack.
9) Tighten the bolts and nuts which hold the lower side of transmission to the engine.
Tightening torque:
50 Nm (5.1 kgf-m, 36.9 ft-lb)
10) Connect the transmission to the engine.
(1) Install the starter.
(2) Tighten the bolts which hold the upper side of the transmission to the engine.
NOTE:
Long bolts are used in the section indicated by the arrows (A) in the figure below.
Tightening torque:
50 Nm (5.1 kgf-m, 36.9 ft-lb)
11) Remove the ST.
12) Install two ground cables.
Tightening torque:
19 Nm (1.9 kgf-m, 14.0 ft-lb)
13) Install the pitching stopper.
Tightening torque:
T1: 50 Nm (5.1 kgf-m, 36.9 ft-lb)
T2: 58 Nm (5.9 kgf-m, 42.8 ft-lb)
14) Lift up the vehicle.
15) Install the front drive shaft into the transmission.
ST 28399SA010 OIL SEAL PROTECTOR
16) Insert the front arm ball joint into the housing lower part, and tighten the mounting bolt.
Tightening torque:
50 Nm (5.1 kgf-m, 36.9 ft-lb)
17) Attach the stabilizer link to the front arm.
Tightening torque:
30 Nm (3.1 kgf-m, 22.1 ft-lb)
18) Attach the gear shift rod and stay.
(1) Attach the gear shift rod to the transmission.
Tightening torque:
12 Nm (1.2 kgf-m, 8.9 ft-lb)
(2) Install the stay to the transmission bracket.
Tightening torque:
18 Nm (1.8 kgf-m, 13.3 ft-lb)
19) Install the propeller shaft.
20) Install the heat shield cover.
21) Install the hanger bracket to the transmission.
Tightening torque:
30 Nm (3.1 kgf-m, 22.1 ft-lb)
22) Install the rear exhaust pipe and muffler.
23) Install the front and center exhaust pipe.
24) Install the under cover.
25) Lower the vehicle.
26) Install the operating cylinder.
Tightening torque:
37 Nm (3.8 kgf-m, 27.3 ft-lb)
27) Install the ground cord.
Tightening torque:
13 Nm (1.3 kgf-m, 9.6 ft-lb)
28) Install the engine hanger rear, and then connect the engine harness connector.
Tightening torque:
21 Nm (2.1 kgf-m, 15.5 ft-lb)
29) Connect the following connectors.
30) Install the air intake boot.
31) Connect the battery ground terminal.
32) Remove the lift arm from vehicle.