Installation
RA61F MANUAL TRANSMISSION: MANUAL TRANSMISSION ASSEMBLY: INSTALLATION
1. INSTALL TRANSFER ASSEMBLY
2. INSTALL MANUAL TRANSMISSION CASE COVER SUB-ASSEMBLY
(a) Install the manual transmission case cover with the 5 bolts.
Torque : 12 Nm (117 kgf-cm, 8 ft-lbf)
3. INSTALL MANUAL TRANSMISSION WITH TRANSFER
(a) Install the manual transmission with transfer with the 9 bolts.
Torque : 71 Nm (724 kgf-cm, 52 ft-lbf) for bolt A
Torque : 37 Nm (377 kgf-cm, 27 ft-lbf) for bolt B
4. CONNECT WIRE HARNESS
5. CONNECT CONNECTOR
(a) Connect the back-up light switch connector.
(b) Connect the speedometer sensor connector.
(c) Connect the 2 transfer indicator switch connectors.
6. INSTALL REAR NO. 1 ENGINE MOUNTING INSULATOR
(a) Install engine mounting insulator rear No. 1 with the 4 bolts.
Torque : 65 Nm (663 kgf-cm, 48 ft-lbf)
7. INSTALL NO. 3 FRAME CROSSMEMBER SUB-ASSEMBLY
(a) Install the No. 3 frame crossmember sub-assembly with the 4 bolts and 4 nuts.
Torque : 72 Nm (734 kgf-cm, 53 ft-lbf)
(b) Install the No. 3 frame crossmember sub-assembly with the 4 bolts.
Torque : 30 Nm (306 kgf-cm, 22 ft-lbf)
8. INSTALL FRONT SUSPENSION MEMBER BRACKET LH
(a) Install the front suspension member bracket LH with the 4 bolts.
Torque : 33 Nm (337 kgf-cm, 24 ft-lbf)
9. INSTALL FRONT SUSPENSION MEMBER BRACKET
(a) Install the front suspension member bracket RH with the 4 bolts.
Torque : 33 Nm (337 kgf-cm, 24 ft-lbf)
10. INSTALL CLUTCH ACCUMULATOR ASSEMBLY Installation
11. INSTALL ACCUMULATOR TO FLEXIBLE HOSE TUBE
(a) Using a union nut wrench, connect the hose tube. (for flexible hose side)
Torque : 20 Nm (199 kgf-cm, 14 ft-lbf)
NOTICE:
Use the formula to calculate special torque values for situations where a union nut wrench is combined with a torque wrench Service Precautions.
(b) Install a new clip.
(c) Using a union nut wrench, connect the hose tube. (for accumulator side)
Torque : 20 Nm (199 kgf-cm, 14 ft-lbf)
NOTICE:
Use the formula to calculate special torque values for situations where a union nut wrench is combined with a torque wrench Service Precautions.
(d) Install the 3 nuts and connect the hose tube.
Torque : 19 Nm (194 kgf-cm, 14 ft-lbf)
12. INSTALL CLUTCH RELEASE CYLINDER ASSEMBLY Installation
13. INSTALL NO. 1 CLUTCH HOUSING COVER Installation
14. INSTALL FLYWHEEL HOUSING SIDE COVER
(a) Install the flywheel housing side cover onto the cylinder block.
15. INSTALL STARTER ASSEMBLY Installation
16. INSTALL MANIFOLD STAY
(a) Install the manifold stay with the 3 bolts.
Torque : 40 Nm (408 kgf-cm, 30 ft-lbf)
17. INSTALL NO. 2 MANIFOLD STAY
(a) Install the No. 2 manifold stay with the 3 bolts.
Torque : 40 Nm (408 kgf-cm, 30 ft-lbf)
18. INSTALL PROPELLER SHAFT ASSEMBLY Installation
19. INSTALL FRONT PROPELLER SHAFT ASSEMBLY Installation
20. INSTALL PROPELLER SHAFT HEAT INSULATOR
(a) Install the propeller shaft heat insulator with the 2 bolts.
Torque : 16 Nm (160 kgf-cm, 12 ft-lbf)
21. INSTALL FRONT EXHAUST PIPE ASSEMBLY Installation
22. INSTALL NO. 2 FRONT EXHAUST PIPE ASSEMBLY Installation
23. ADD MANUAL TRANSMISSION OIL
24. ADJUST MANUAL TRANSMISSION OIL Testing and Inspection
25. INSTALL FLOOR SHIFT SHIFT LEVER ASSEMBLY
(a) Apply MP grease to the tip of the shift lever.
(b) Cover the shift lever cap with a cloth.
(c) Pressing down on the shift lever cap, turn it clockwise to install the shift lever.
26. REMOVE TRANSFER HIGH AND LOW SHIFT LEVER ASSEMBLY
(a) Install the transfer shift lever onto the shift lever retainer.
(b) Using needle-nose pliers, install the snap ring.
27. INSTALL SHIFT LEVER BOOT ASSEMBLY
(a) Install the shift lever boot with the 4 screws and 2 clips.
28. INSTALL SHIFT LEVER KNOB SUB-ASSEMBLY (for Manual transmission)
29. INSTALL SHIFT LEVER KNOB SUB-ASSEMBLY (for Transfer)
30. INSTALL FRONT CONSOLE BOX Installation
31. INSTALL CONSOLE UPPER REAR PANEL SUB-ASSEMBLY Installation
32. INSTALL PARKING BRAKE HOLE COVER SUB-ASSEMBLY Installation
33. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
Torque : 3.9 Nm (40 kgf-cm, 35 in-lbf)
34. CHECK FOR EXHAUST GAS LEAKAGE