Transmission Installation

Manual Transmission Assembly

INSTALLATION
1. Install the rear cushion rubber to transmission assembly.
Tightening torque: 35 Nm (3.6 kgf-cm, 26 ft. lbs.)
2. Install the transmission onto engine.
1. Gradually raise the transmission with transmission jack.
2. Loosen the turnbuckle of ST to return the engine assembly to its original position.
3. Engage them at splines.

NOTE: Be careful not to strike the main shaft against clutch housing cover.





3. Install the transmission rear crossmember.
Tightening torque:
T1: 75 Nm (7.6 kgf-cm, 55 ft. lbs.)
T2: 140 Nm (14.3 kgf-cm, 103 ft. lbs.)
4. Take out the transmission jack.





5. Tighten the nuts which hold lower side of transmission to engine.
Tightening torque: 50 Nm (5.1 kgf-cm, 36.9 ft. lbs.)





6. Connect the transmission to engine.
1. Install the starter.
2. Tighten the bolts that hold upper side of transmission to engine.
Tightening torque: 50 Nm {5.1 kgf-cm. 36.9 ft. lbs.)





7. Remove the ST.





8. Install the pitching stopper.
Tightening torque:
T1: 50 Nm (5.1 kgf-cm, 37 ft. lbs.)
T2: 58 Nm (5.9 kgf-cm, 43 ft. lbs.)
9. Lift-up the vehicle.
10. Install the front drive shaft into transmission.





11. Replace the differential side retainer oil seal.
ST 18675AA000 DIFFERENTIAL SIDE OIL SEAL INSTALLER

NOTE: Be sure to replace the differential side retainer oil seal after the procedure of removing the front drive shaft.





12. Install the front drive shaft into transmission.
ST 28399SA010 FRONT DRIVE SHAFT OIL SEAL PROTECTOR





13. Install the ball joint of lower arm.
Tightening torque: 49 Nm (5.0 kgf-cm, 36 ft. lbs.)





14. Install the stabilizer link into front arm.
Tightening torque: 45 Nm (4.6 kgf-cm, 33.2 ft. lbs.)
15. Install the gear shift rod and stay.





1. Install the gear shift rod into transmission.
2. Install the stay onto transmission.
16. Install the propeller shaft.
17. Install the heat shield cover. (if equipped)
18. Install the rear exhaust pipe and muffler.
19. Install the front and center exhaust pipe. (Non-turbo model).
20. Install the center exhaust pipe. (Turbo model)





21. Install the operating cylinder.
Tightening torque: 37 Nm (3.8 kgf-cm, 27.5 ft. lbs.)
22. Connect the following connectors:
1. Transmission ground cable
Tightening torque: 13 Nm (1.3 kgf-cm, 9.4 ft. lbs.)
2. Neutral position switch connector
3. Back-up light switch connector
23. Fill transmission gear oil through the transmission level gauge hole.
24. Install the air intake chamber stay. (Non-turbo model).
Tightening torque: 16 Nm (1.6 kgf-cm, 11.6 ft. lbs.)
25. Install the air intake chamber and air cleaner case. (Non-turbo model)
26. Install the intercooler. (Turbo model)
27. Connect the battery ground cable to battery.
28. Take off the vehicle from lift arms.