Manual Transmission Removal and Installation

DISMOUNTING OF TRANS. UNIT
IN CABIN





Remove transmission shift control lever and transfer shift control lever knob.

IN ENGINE ROOM
1. Disconnect negative (-) cable of battery.
2. Remove breather hose from clamp at the rear end of cylinder head.
3. Undo clamp at the rear end of intake manifold to free wiring harness.





4. Disconnect wiring harness coupler.





5. Remove starter motor fixing nuts and remove starter.





6. Remove transmission fastening bolts.

ON LIFT





1. Drain oil from transmission and transfer.
2. Give match marks on joint flange and propeller shaft as shown in figure (front and rear).
3. Remove flange bolts of rear propeller shaft universal joint and pull out propeller shaft.
4. Remove flange bolts of front propeller shaft universal joint and pull out propeller shaft.
5. Separate clutch cable end.

NOTE:
- It is not necessary to drain transmission oil when dismounting transmission and transfer for clutch maintenance only.
- Work without draining transfer oil is possible if front propeller shaft is dismounted together with transmission and transfer.

6. Remove clutch housing lower plate.





7. Take off exhaust center pipe.





8. Remove nut where meter cable is connected and disengage cable from transfer.
9. Remove transmission stiffeners (right and left) and remove nuts from joint with engine.





10. Apply transmission jack and remove engine rear mounting member taking off its bolts.
11. After removing mounting member, move rearward transmission and transfer assemblies placed on jack and then lower them.





12. Remove wiring harness and breather hose.
13. Separate gear shift lever case and transfer assembly 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) & (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 transmission and transfer with gear oil as specified.
- Connect battery and check function of engine, clutch and trans.
- When installing propeller shaft, align the match marks.