Installation

INSTALLATION
1. Clean all mating faces and relevant parts.

WARNING: ENSURE CORRECT USE OF LIFT INCLUDING SIDE CLAMPS, SECURING PEG AND SAFETY CHAIN AS APPROPRIATE





2. Position an Epco V -100 or similar lift under the ramp with the transmission unit installed on the lift.
- Pass the safety chain over the transmission unit, engage in the side arm of the lift and tighten the chain adjuster.





3. Install the transmission unit.
- Raise the lift and position the transmission unit to the engine.





NOTE: The arrows are shown as viewed from the rear of the vehicle.

4. Install two lower and two upper transmission unit to engine securing bolts to align the unit correctly.
5. Lower and remove the lift.
- Release the safety chain and side clamps.





5. Install the transmission unit to engine securing bolt which also secures the fluid cooler pipe.





7. Install the engine harness multiplug mounting bracket.
- Install the bracket to transmission unit securing bolts.
8. Install the remaining transmission unit to engine securing bolts.





9. Secure the torque converter, as follows:
1. Loosely assemble the six (6) drive plate to torque converter securing bolts.
- While preventing crankshaft rotation, tighten ALL converter bolts to specification.
2. Fit the blanking plug to the cylinder block access hole.





10. Fit the transmission harness to the transmission unit, as follows:
1. Connect the harness multiplug.
2. Secure the harness locking lever.





11. Fit the gear selector cable to the transmission unit, as follows:
1. Install the selector cable to transmission casing securing bolts.
2. Install the selector cable ball pin to selector lever securing nut.





12. Install the rotary switch, as follows:
1. Fit the switch harness to the flange clamps.
2. Install the switch securing bolts.





13. Tighten the engine support hook nuts to raise the transmission unit.





14. Install the driveshaft.
- Align the driveshaft with the transmission drive flange and tighten the axings to specification.





15. Install the rear engine mounting bracket, as follows:
1. Position the rear engine mounting bracket and install the mounting to bracket securing bolt.
2. Using a ramp jacking channel, position a jack under the rear engine mounting point.
3. With a suitable piece of wood on the jack head, operate the jack to raise the mounting bracket into position.
4. Install the mounting bracket to body securing bolts.
16. Lower the jack.





17. Connect the fluid cooler pipes to the transmission unit.
- Remove the blanking plugs from the pipes and transmission unit.
- Install new O-rings.
- Tighten the union nuts.





18. Install the left and right-hand downpipe catalyst converter mounting brackets.
- Install the bracket to transmission unit securing bolts.





19. Remove engine support MS - 53C or equivalent, as follows:
1. Slacken the support hook nuts.
2. Disengage the support hooks from the lifting brackets.





20. Remove engine lifting bracket JD - 222 or equivalent, from the rear right-hand position.
- Remove the lifting bracket to engine securing bolt.





21. Remove engine lifting bracket JD - 222 from the rear left-hand position.
- Remove the lifting bracket to engine securing bolt.





22. Install the coolant header tank, as follows:
1. Position the header tank dowels on the mounting grommets.
2. Install the securing bolt.
23. Install the left and right-hand downpipe catalytic converters.
24. Install the front muffler.
25. Install the air intake components.
26. Connect the battery.
27. Fill the transmission unit with fluid.