5MT

Manual Transmission Assembly

INSTALLATION

1) Replace the differential side retainer oil seal.
ST 18675AA000 DIFFERENTIAL SIDE OIL SEAL INSTALLER

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





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, and tighten the 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.

Tightening torque:
50 Nm (5.1 kgf-m, 36.9 ft-lb)





11) Remove the ST.





12) 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)





13) Lift up the vehicle.
14) Install the front drive shaft into the transmission.
ST 28399SA010 OIL SEAL PROTECTOR





15) 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)





16) Attach the stabilizer link to the front arm.

Tightening torque:
30 Nm (3.1 kgf-m, 22.1 ft-lb)





17) 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)

18) Install the propeller shaft.
19) Install the heat shield cover.
20) Install the hanger bracket to the transmission.





21) Install the rear exhaust pipe and muffler.
22) Install the center exhaust pipe.
23) Install the under cover.
24) Install the operating cylinder.

Tightening torque:
37 Nm (3.8 kgf-m, 27.3 ft-lb)





25) Install the transmission radio ground terminal.

Tightening torque:
13 Nm (1.3 kgf-m, 9.6 ft-lb)





26) Install the engine hanger.

Tightening torque:
16 Nm (1.6 kgf-m, 11.8 ft-lb)





27) Connect the following connectors.





28) Install the intercooler.
29) Connect the battery ground terminal.
30) Remove the lift arm from vehicle.