Manual Transmission Removal and Installation
DISMOUNTING OF TRANS. UNITIn Cabin
Remove transmission shift control lever.
In Engine Room
1. Disconnect negative (-) cable of battery.
2. Remove breather hose (1) from clamp (2) at the rear end of cylinder head.
3. Undo clamp (3) at the rear end of intake manifold (4) to free wiring harness.
4. Disconnect wiring harness coupler.
5. Remove starter motor fixing bolts and remove starter.
6. Remove transmission fastening bolts.
On Lift
1. Drain oil from transmission.
2. Give match marks (1) on joint flange and propeller shaft as shown in figure. Remove flange bolts of propeller shaft universal joint and pull out propeller shaft.
3. Separate clutch cable end.
4. Remove clutch housing lower plate.
5. Take off exhaust center pipe (1).
6. Disconnect meter cable (2) from transmission.
7. Remove transmission stiffeners (right and left) and remove nuts from joint with engine.
8. Apply transmission jack (1) and remove engine rear mounting member bolts.
9. After removing mounting member bolts, move rearward transmission assembly placed on jack and then lower them.
10. Remove wiring harness (1) and breather hose (2).
11. Separate gear shift lever case (3) and extension case (4) from transmission.
REMOUNTING
For remounting, reverse dismounting procedure.
Use specified torque as given below.
Tightening Torque
(a): 85 Nm (8.5 kg-m, 61.5 ft. lbs.)
(b), (c), (d) and (e):50 Nm (5.0 kg-m, 36.5 ft. lbs.)
(f): 55 Nm (5.5 kg-m, 40.0 ft. lbs.)
- Set each clamp for wiring, hose and cable securely.
- Set clamp for shift control lever boots securely.
- After connecting clutch cable, be sure to adjust its play properly.
Arm play "a": 0.5 -1.5 mm (0.02 - 0.06 inch)
[Pedal play 15 - 25 mm (0.6 -1.0 inch)]
- Fill gear oil to transmission as specified.
- Connect battery and check function of engine, clutch and transmission.