Installation

R155F MANUAL TRANSMISSION: MANUAL TRANSMISSION ASSEMBLY: INSTALLATION

1. INSTALL TRANSFER ASSEMBLY Installation

2. INSTALL MANUAL TRANSMISSION WITH TRANSFER





(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 A37 Nm (379 kgf-cm, 27 ft-lbf) for bolt B and C

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

3. CONNECT WIRE HARNESS

(a) Connect the wire harness clamp to the transmission w/ transfer assembly.

(b) Connect the back-up lamp switch connector.

(c) Connect the speed sensor connector.

(d) Connect the 2 transfer indicator switch connectors.

(e) Connect the transfer shift actuator motor connector.

4. INSTALL NO. 1 ENGINE MOUNTING INSULATOR REAR





(a) Install the engine mount insulator rear No. 1 with 4 bolts onto the transmission assembly.

Torque : 65 Nm (663 kgf-cm, 48 ft-lbf)

5. 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)

6. INSTALL CLUTCH RELEASE CYLINDER ASSEMBLY





(a) Install the clutch release cylinder assembly with the 2 bolts.

Torque : 12 Nm (122 kgf-cm, 9 ft-lbf)

7. INSTALL STARTER ASSEMBLY Installation

8. 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

9. INSTALL PROPELLER WITH CENTER BEARING SHAFT ASSEMBLY (for Access Cab) Installation

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

11. INSTALL FRONT PROPELLER SHAFT ASSEMBLY Installation

12. INSTALL FRONT EXHAUST PIPE ASSEMBLY Installation

13. ADD MANUAL TRANSMISSION OIL

14. ADJUST MANUAL TRANSMISSION OIL R155F Manual Transmission

15. 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)

16. INSTALL FLOOR SHIFT SHIFT LEVER ASSEMBLY





(a) Cover the shift lever cap with a cloth.

(b) While pressing down on the shift lever, turn it clockwise to install.

HINT
Apply MP grease to the tip of the shift lever.

17. INSTALL SHIFT LEVER BOOT ASSEMBLY





(a) Install the shift lever boot assembly with the 2 screws A and 2 clips B.

18. INSTALL FRONT CONSOLE BOX (for Bench Seat Type) Installation

19. INSTALL FRONT CONSOLE BOX (for Separate Seat Type) Installation

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

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

22. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

Torque : 3.9 Nm (40 kgf-cm, 35 in-lbf)

23. CHECK FOR MANUAL TRANSMISSION OIL LEAKAGE