Transmission Replacement
Transmission Replacement
Removal Procedure
1. Turn the steering wheel so that the front wheels are pointing straight ahead.
2. Turn the ignition lock cylinder to the lock position and remove the key.
3. Remove the heater inlet and outlet pipes from the vehicle. Refer to Heater Inlet And Outlet Pipe Replacement (Heater Inlet And Outlet Pipe Replacement)
4. Remove the shift control rods from the transmission. Refer to Shift Control Assembly Replacement (Shift Control Assembly Replacement).
5. Remove the exhaust system. Refer to Exhaust Muffler with Resonator, Exhaust, and Tail Pipe Replacement (Exhaust Muffler with Resonator, Exhaust, and Tail Pipe Replacement).
6. Remove the propeller shaft. Refer to Two-Piece Propeller Shaft Replacement (Two-Piece Propeller Shaft Replacement).
7. Disconnect the electrical connector from the vehicle speed sensor.
8. Disconnect the electrical connector (4) from the backup lamp switch.
9. Remove the electrical harness retainers (1) from the transmission.
10. Position the electrical harness (2) out of the way.
11. Remove the electrical harness retainers (2) from the transmission.
12. Position the electrical harness (1) out of the way.
13. Support and secure the transmission with a suitable transmission jack.
14. Remove the transmission support. Refer to Transmission Mount Replacement (Aisin AY6 - Manual Transmission).
15. Remove the clutch hydraulic hose retaining clip (1) from the clutch slave cylinder.
16. Disconnect the clutch hydraulic hose (2) from the clutch slave cylinder. Plug the lower hose end to prevent fluid loss.
17. Remove the transmission bolts (1-6).
18. Pull the transmission free from the engine dowels.
Note: Ensure clearance is maintained between the transmission and the following:
* The clutch assembly
* The input shaft
* The catalytic converters
* The wiring harnesses
* The propeller shaft
19. Using the transmission jack, carefully lower the transmission from the vehicle.
Installation Procedure
Note: Ensure clearance is maintained between the transmission and the following:
* The clutch assembly
* The input shaft
* The catalytic converters
* The wiring harnesses
* The propeller shaft
1. Using the transmission jack, carefully raise the transmission to the vehicle.
2. Align the transmission with the engine dowels.
Caution: Refer to Fastener Caution (Fastener Caution).
3. Install the transmission bolts (1-6) and tighten to 50 Nm (37 lb ft).
4. Install the clutch hydraulic hose retaining clip (1) to the clutch slave cylinder.
Note: Ensure the clutch hydraulic hose is routed in an upward direction above the clutch slave cylinder with no sharp bends, kinks, or downward loops. Ensure the clutch hydraulic hose does not come in contact with any sharp or potentially hot surfaces.
5. Install the clutch hydraulic hose to the vehicle.
6. Align the clutch hydraulic hose locating tab with the notch in the slave cylinder hose fitting.
7. Push the clutch hydraulic hose (2) into the clutch slave cylinder until a "click" is heard.
8. Tug gently on the clutch hydraulic hose (2) to ensure proper retention to the clutch slave cylinder.
9. Install the shift control rods to the transmission. Refer to Shift Control Assembly Replacement (Shift Control Assembly Replacement).
10. Remove the transmission jack.
11. Install the transmission support. Refer to Transmission Mount Replacement (Aisin AY6 - Manual Transmission).
12. Install the electrical harness retainers (2) to the transmission.
13. Install the electrical harness retainers (1) to the transmission.
14. Connect the electrical connector (4) to the backup lamp switch.
15. Connect the electrical connector to the vehicle speed sensor.
16. Install the propeller shaft. Refer to Two-Piece Propeller Shaft Replacement (Two-Piece Propeller Shaft Replacement).
17. Install the exhaust system. Refer to Exhaust Muffler with Resonator, Exhaust, and Tail Pipe Replacement (Exhaust Muffler with Resonator, Exhaust, and Tail Pipe Replacement).
18. Inspect the transmission fluid level.
19. Lower the vehicle.
20. Install the heater inlet and outlet pipes in the vehicle. Refer to Heater Inlet And Outlet Pipe Replacement (Heater Inlet And Outlet Pipe Replacement)
21. Install the transmission control lever knob. Refer to Transmission Control Lever Knob Replacement (Transmission Control Lever Knob Replacement).
22. Bleed the clutch hydraulic system. Refer to Hydraulic Clutch System Bleeding (Service and Repair).
Transmission Final Test and Inspection
Complete the following procedure after the transmission is installed in the vehicle:
1. With the ignition OFF or disconnected and clutch pedal depressed, crank the engine several times. Listen for any unusual noises or evidence that any parts are binding.
2. Place transmission in neutral, start the engine and listen for any unusual noises or evidence that any parts are binding.
3. While the engine continues to idle raise and support the vehicle.
4. Perform a final inspection for the proper fluid level.
5. Lower the vehicle.
6. Road test the vehicle.