Installation
INSTALLATION1) Attach the ST to converter case.
ST 498277200 STOPPER SET
2) When completely overhauling the transmission, refill CVTF through the transmission right side plug.
3) Replace the front differential side retainer oil seal.
NOTE:
^ Be sure to replace the differential side retainer oil seal with a new part whenever the front drive shaft is removed from the transmission.
^ When a new differential side retainer oil seal has been installed, replacement is not required.
4) Install the rear cushion rubber on the transmission.
Tightening torque:
40 Nm (4.1 kgf-m, 29.5 ft-lb)
5) Mount the transmission onto the transmission jack.
6) Strike and bend the transmission hanger of transmission rear with a rubber hammer etc. so that it gets in contact with the transmission case.
CAUTION:
Do not apply extra overload or impact to the transmission case.
7) Remove the pitching stopper bracket, if mounted.
8) Install the transmission onto the engine.
NOTE:
^ While raising the transmission jack gradually, turn the screw of engine support, then tilt the engine forward.
^ Temporarily attach the two engine connecting bolts and two nuts (lower side).
9) Install the transmission rear crossmember.
Tightening torque:
T1: 35 Nm (3.6 kgf-m, 25.8 ft-lb)
T2: 70 Nm (7.1 kgf-m, 51.6 ft-lb)
10) Tighten the two engine connecting bolts and two nuts (lower side).
Tightening torque:
50 Nm (5.1 kgf-m, 36.9 ft-lb)
11) Remove the transmission jack.
12) Lower the vehicle.
13) Install the three engine mounting bolts (upper side).
Tightening torque:
50 Nm (5.1 kgf-m, 36.9 ft-lb)
14) Remove the ST (STOPPER SET) from converter case.
15) Remove the ST (ENGINE SUPPORT BRACKET and ENGINE SUPPORT).
ST1 41099AA010 ENGINE SUPPORT BRACKET
ST2 41099AA020 ENGINE SUPPORT
16) Match the torque converter screw hole with drive plate hole to install the bolt.
CAUTION:
^ Do not drop the mounting bolt in the converter housing.
^ Do not damage the mounting bolt.
Tightening torque:
25 Nm (2.5 kgf-m, 18.4 ft-lb)
17) Install the remaining three bolts by rotating the crank pulley a little at a time in the same direction as engine revolution.
Tightening torque:
25 Nm (2.5 kgf-m, 18.4 ft-lb)
18) Install the service hole plug.
19) Install the engine ground terminals.
Tightening torque:
19 Nm (1.9 kgf-m, 14.0 ft-lb)
20) Replace the CVTF inlet hose and CVTF outlet hose.
21) Install the CVTF inlet hose and CVTF outlet hose to transmission.
22) Install the CVTF cooler (with warmer feature) to the transmission.
Tightening torque:
23 Nm (2.3 kgf-m, 17.0 ft-lb)
23) Install the starter.
24) Install the engine hanger rear.
Tightening torque:
21 Nm (2.1 kgf-m, 15.5 ft-lb)
25) Install the pitching stopper bracket and transmission radio ground cord.
Tightening torque:
41 Nm (4.2 kgf-m, 30.2 ft-lb)
26) Install the air breather hose to the pitching stopper bracket.
27) 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)
28) Connect the EGR control valve harness connector, throttle position sensor harness connector and manifold pressure sensor harness connector.
Tightening torque:
Bulkhead harness connector bracket
7.5 Nm (0.8 kgf-m, 5.5 ft-lb)
29) Lift up the vehicle.
30) Apply grease to the side retainer oil seal lip.
31) Set the ST to side retainer.
ST 28399SA010 OIL SEAL PROTECTOR
32) Replace the circlip of the drive shaft with a new part.
33) Insert the front drive shaft spline section into transmission and remove the ST (OIL SEAL PROTECTOR).
NOTE:
^ Before inserting RH front drive shaft into transmission, turn the steering wheel to left hand full lock.
^ Before inserting LH front drive shaft into transmission, turn the steering wheel to right hand full lock.
34) Insert the drive shaft into the transmission securely by pressing the housing from outside of the vehicle.
35) Insert the ball joint into housing and secure with bolt.
Tightening torque:
50 Nm (5.1 kgf-m, 36.9 ft-lb)
CAUTION:
^ Do not apply grease to the tapered portion of ball stud.
^ Before tightening, make sure the lower side of housing and stepped section of ball joint are in contact.
36) Install the stabilizer bracket.
Tightening torque:
25 Nm (2.5 kgf-m, 18.4 ft-lb)
37) Install the jack-up plate.
Tightening torque:
60 Nm (6.1 kgf-m, 44.3 ft-lb)
38) Install the plate assembly to transmission.
Tightening torque:
25 Nm (2.5 kgf-m, 18.4 ft-lb)
39) Install the washer and snap pin to the shifter arm.
40) Install the propeller shaft.
41) Install the center exhaust cover.
Tightening torque:
18 Nm (1.8 kgf-m, 13.3 ft-lb)
42) Install the center exhaust pipe.
43) Install the under cover.
44) Lower the vehicle.
45) Connect the following harness connectors.
^ Transmission harness connectors
^ Inhibitor harness connector
^ Transmission radio ground terminal
Tightening torque:
13 Nm (1.3 kgf-m, 9.6 ft-lb)
46) Install the air intake boot assembly.
47) Install the front wheels.
48) Connect the battery ground terminal.
49) Refill differential gear oil to adjust the differential gear oil amount.
50) Refill CVTF to adjust the CVTF level.
51) Perform Clear Memory 2 operation. Clearing Reading Diagnostic Trouble Codes
52) Perform the diagnosis again. Programming and Relearning
53) Execute the rear differential inspection mode.
CAUTION:
Always execute the rear differential inspection mode at the replacement of the following.
^ Replacement of transmission assembly
^ Replacement of front differential hypoid gear set
54) Perform the road test to make sure there is no fault. Road Test