Transmission Installation
Manual Transmission AssemblyINSTALLATION
1) Set the release fork, release bearing and release shaft to the transmission.
2) Replace the front differential side retainer oil seal.
(1) Remove the oil seal by using flat tip screwdriver etc.
(2) Apply gear oil to the lip of new oil seals.
(3) Install a new oil seal using ST.
ST 18675AA000 DIFFERENTIAL SIDE OIL SEAL INSTALLER
NOTE: Be sure to replace the differential side oil seal after the procedure of removing front drive shaft from transmission.
3) Loosen the turnbuckle of ST to return the engine to its original position.
4) Install the transmission.
5) Tighten the bolts and nuts which hold the lower side of transmission to the engine.
NOTE:
^ Make sure that the main shaft spline is completely inserted.
^ Make sure that the rear end of the engine is set low.
6) Move the transmission to the right side of the vehicle, and attach the joint COMPL, stay bolts and reverse check cable.
7) Install the front cross-member and rear cross-member.
8) Tighten the bolts which hold the upper side of the transmission to the engine.
9) Make sure that the release bearing is completely inserted.
NOTE:
^ Push the release fork towards the operating cylinder side until a clicking sound is heard. Pull the release fork towards the engine side. If the release fork is not in contact with the case, the setting is complete.
^ Confirm that the boot cover is set securely.
10) Install the pitching stopper bracket.
Tightening torque:
41 Nm (4.2 kgf-m, 30.2 ft-lb)
11) Install the pitching stopper.
12) Install the clutch operating cylinder.
Tightening torque:
41 Nm (4.2 kgf-m, 30.2 ft-lb)
NOTE: Check that the clutch hose is routed properly.
13) Install the starter assembly.
14) Attach the ground cable to the transmission and body.
15) Connect the following harness connectors, then attach the engine hanger rear.
16) Set the ST to side retainer.
ST 28399SA010 OIL SEAL PROTECTOR
17) Install the front drive shaft into the transmission.
NOTE: Replace the circlip of drive shaft with a new part.
18) Install the front drive shaft into transmission, remove the ST and insert the drive shaft securely.
ST 28399SA010 OIL SEAL PROTECTOR
19) Install the ball joint of the front arm.
20) Install the front stabilizer link.
Tightening torque:
45 Nm (4.6 kgf-m, 33.2 ft-lb)
NOTE: Use a new self-locking nut.
21) Install the heat shield cover. (If equipped)
22) Install the propeller shaft.
23) Install the rear exhaust pipe and muffler.
24) Install the center exhaust pipe.
25) Fill the transmission gear oil.
26) Install the intercooler.
27) Install the collector cover.
28) Connect the battery ground cable to the battery.