Installation

R155 MANUAL TRANSMISSION ASSEMBLY:

INSTALLATION





1. INSTALL MANUAL TRANSMISSION UNIT ASSEMBLY
(a) Align the input shaft with the clutch disc and install the transmission unit assembly onto the engine.
(b) Install the 7 bolts.
Torque: 72 Nm (730 kgf-cm, 53 ft-lbf) for bolt A
Torque: 37 Nm (379 kgf-cm, 27 ft-lbf) for bolt B and C

HINT: Install bolt B from the direction of the front of the vehicle.

2. CONNECT WIRE HARNESS
(a) Connect the wire harness clamp to the transmission assembly.
(b) Connect the back-up lamp switch connector.
(c) Connect the speed sensor connector.





3. INSTALL NO. 1 ENGINE MOUNTING INSULATOR REAR
(a) Install the engine mount insulator rear No. 1 onto the transmission assembly with 4 bolts.
Torque: 65 Nm (663 kgf-cm, 48 ft-lbf)





4. INSTALL NO. 3 FRAME CROSSMEMBER SUB-ASSEMBLY
(a) Install the frame crossmember sub-assembly No. 3 with the 8 bolts and nuts.
Torque: 40 Nm (408 kgf-cm, 30 ft-lbf)
(b) Install the 4 bolts onto the engine mounting insulator rear No. 1.
Torque: 19 Nm (189 kgf-cm, 14 ft-lbf)





5. INSTALL CLUTCH RELEASE CYLINDER ASSEMBLY
(a) Install the clutch release cylinder assembly with the 2 bolts.
Torque: 12 Nm (120 kgf-cm, 9 ft-lbf)
6. INSTALL STARTER ASSEMBLY





7. INSTALL MANIFOLD STAY
(a) Install the manifold stay with the 3 bolts.
Torque: 72 Nm (730 kgf-cm, 53 ft-lbf) for bolt A
Torque: 44 Nm (449 kgf-cm, 33 ft-lbf) for bolt B
Torque: 30 Nm (306 kgf-cm, 22 ft-lbf) for bolt C
8. INSTALL PROPELLER WITH CENTER BEARING SHAFT ASSEMBLY (for Access Cab) (Installation)

9. INSTALL PROPELLER SHAFT ASSEMBLY (for Regular Cab) (Installation)

10. INSTALL FRONT EXHAUST PIPE ASSEMBLY

11. ADD MANUAL TRANSMISSION OIL
12. ADJUST MANUAL TRANSMISSION OIL (Testing and Inspection)

13. INSTALL NO. 2 ENGINE UNDER COVER SUB-ASSEMBLY
(a) Install the engine under cover No. 2 with the 4 bolts.
Torque: 30 Nm (306 kgf-cm, 22 ft-lbf)





14. INSTALL FLOOR SHIFT SHIFT LEVER ASSEMBLY
(a) Cover the shift lever cap with a cloth.
(b) While pressing down on the shift lever cap, turn it clockwise to install.

NOTE: Apply MP grease to the tip of the shift lever.





15. INSTALL SHIFT LEVER BOOT ASSEMBLY
(a) Install the shift lever boot assembly with the 2 screws A and 2 clips B.
16. INSTALL FRONT CONSOLE BOX (for Bench Seat Type)

17. INSTALL FRONT CONSOLE BOX (for Separate Seat Type)

18. INSTALL REAR CONSOLE BOX ASSEMBLY (for Separate Seat Type)

19. INSTALL CONSOLE UPPER REAR PANEL SUB-ASSEMBLY (for Separate Seat Type)

20. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
Torque: 3.9 Nm (40 kgf-cm, 35 in-lbf)
21. CHECK FOR MANUAL TRANSMISSION OIL LEAKAGE