Installation
NOTE:
Check that the two dowel pins are installed in the clutch housing.
Use only Super High Temp Urea Grease (P/N 08798-9002).
1. Place the transmission on the transmission jack, and raise it to the engine level.
2. Set the release fork to the clutch housing.
3. Install the two transmission housing mounting bolts and engine stiffener.
4. Install the three rear transmission mounting bolts.
5. Loosen the front engine mounting bolt, then install the two front engine
mounting bolts to the transmission side.
6. Remove the transmission jack.
7. Install the clutch housing cover.
Corrosion resistant bolt/nut
DOWEL PINS
(P/N 08798-9002)
REAR TRANSMISSION
MOUNTING BOLTS
12 x 1.25 mm
105 N.m
(10.5 kg-m, 76 Ib-ft)
(P/lN 08798-9002)
TRANSMISSION HOUSING
MOUNTING BOLTS
12 x 1.25 mm
65 N.m (6.5 kg-m, 47 Ib-ft)
FRONT ENGINE
MOUNTING BOLT
10 x 1.25 mm
60 N.m (6.5 kg-m, 43 Ib-ft)
8 x 1.25 mm
22 N.m (2.2 kg-m, 16 Ib-ft)
6 x 1.0 mm
12 N.m (1.2 kg-m,
9 Ib-ft)
CLUTCH HOUSING
COVER10 x 1.25 mm
45 N.m (4.5 kg-m, 33 Ib-ft)
TRANSMISSION HOUSING MOUNTING BOLT
12 x 1.25 mm
65 N.m (6.5 kg-m, 47 Ib-ft)
TRANSMISSION
JACK
8. Install the release fork in the release hanger, then install the slave cylinder.
9. Connect the shift cable and select cable.
CAUTION: Take care not to bend the cables.
10. Install the upper cover, change wire bracket and lower cover.
11. Install the upper control arm mounting bolt.
Corrosion resistant bolt/nut
8 x 1.25 mm
22 N.m (2.2 kg-m,
16 Ib-ft)
UPPER COVER
COTTER PIN
Replace.
6 x 1.0 mm
12 N.m (1.2 kg-m,
9 Ib-ft)
CHANGE
WIRE
BRACKET
8 x 1.25 mm
26 N.m (2.6 kg-m, 19 Ib-ft)
6 x 1.0 mm
12 N.m (1.2 kg-m, 9 Ib-ft)
LOWER
COVER
UPPER CONTROL ARM MOUNTING BOLT
10 x 1.25 mm
60 N.m (6.0 kg-m. 43 Ib-ft)
(Silicone Grease)
SLAVE CYLINDER
12. Install a new set ring on the end of the left driveshaft and intermediate shaft.
13. Install the left driveshaft.
14. Install the lower control arm to the side beam (see section 18).
CAUTION: Align the reference marks on the adjusting bolt, adjusting cam and lower control arm.
1 5. Install the damper fork bolt (see section 18).
16. Install the toe control arm to the side beam (see section 18).
CAUTION: Make sure that the arrow marks on the toe control arm are aligned.
17. Install the wheel sensor wire clamp and parking brake cable holder.
Corrosion resistant bolt/nut
CASTLE NUT
12 x 1.25 mm
95 N.m (9.5 kg-m, 69 Ib-ft)
DAMPER
FORK BOLT
6 x 1.0 mm
10 N.m
(1.0 kg-m, 7 Ib-ft)
WHEEL SENSOR WIRE CLAMP
LOWER CONTROL ARM
SELF-LOCKING NUT
Replace.
14 x 1.5 mm
125 N.m
(12.5 kg-m. 90 Ib-ft)
ADJUSTING
BOLT
ADJUSTING
CAM
18. Install the intermediate shaft and tighten the intermediate shaft mounting bolts to the intermediate shaft support
base.
19. Install the intermediate shaft heat cover.
Corrosion resistant bolt/nut
SET RING
Replace.
13-49
(cont’d)INTERMEDIATE SHAFT
8 x 1.25 mm
22 N.m
(2.2 kg-m, 16 Ib-ft)
HEAT COVER
6 x 1.0 mm
10 N.m (1.0 kg-m. 7 Ib-ft)
SUPPORT BASE
SELF-LOCKING NUT
Replace.
14 x 1.5 mm
125 N.m (12.5 kg-m, 90 Ib-ft)
SET RING
Replace.
TOE CONTROL ARM
FLANGE BOLT
12 x 1.25 mm
95 N.m
(9.5 kg-m, 69 Ib-ft)
8 x 1.25 mm
22 N.m (2.2 kg-m, 16 Ib-ft)
PARKING BRAKE CABLE HOLDER
SELF-LOCKING NUT
Replace.
12 x 1.25 mm
85 N.m (8.5 kg-m, 62 Ib-ft)
Transmission Assembly
Installation (cont’d)
20. Install the right driveshaft onto the intermediate shaft.
21. Install the lower control arm to the side beam (see section 18).
CAUTION: Align the reference marks on the adjusting bolt, adjusting cam and lower control arm.
22. Install the damper fork bolt (see section 18).
23. Install the toe control arm to the side beam (see section 18).
CAUTION: Make sure that the arrow marks on the toe control arm are aligned.
24. Install the wheel sensor wire clamp and parking brake cable holder.
Corrosion resistant bolt/nut SELF-LOCKING NUT
Replace.
12 x 1.25 mm
85 N.m (8.5 kg-m, 62 Ib-ft)
8 x 1.25 mm
22 N.m (2.2 kg-m,
16 Ib-ft)
PARKING BRAKE
CABLE HOLDER
FLANGE BOLT
12 x 1.25 mm
95 N.m (9.5 kg-m, 69 Ib-ft)
TOE CONTROL ARM
SELF-LOCKING NUT
Replace.
14 x 1.5 mm
125 N.m (12.5 kg-m, 90 Ib-ft)
ADJUSTING CAM
25. Install the front exhaust pipe A.
26. Install the rear beam rod.
27. Install the parking brake cable holders to the rear beam rod.
ADJUSTING BOLT
SELF-LOCKING NUT
Replace.
10 x 1.25 mm
34 N.m (3.4 kg-m, 25 Ib-ft)
GASKET
Replace.
Corrosion resistant bolt/nut
SELF-LOCKING NUT
Replace.
14 x 1.5 mm
125 N.m (12.5 kg-m, 90 Ib-ft)
LOWER CONTROL ARM
WHEEL SENSOR WIRE CLAMP
6 x 1.0 mm
10 N.m 11.0 kg-m, 7 Ib-ft)
CASTLE NUT
12 x 1.25 mm
95 N.m (9.5 kg-m, 69 Ib-ft)
DAMPER
FORK BOLT
EXHAUST
PIPE A
GASKET
Replace.
REAR BEAM ROD
10 x 1.25 mm
60 N.m (6.0 kg-m,
43 Ib-ft)
8 x 1.25 mm
22 N.m (2.2 kg-m,
16 Ib-ft)
SELF LOCKING NUT
Replace.
10 x 1.25 mm
55 N.m (5.5 kg-m, 40-lb-ft)
10 x 1.25 mm
60 N.m (6.0 kg-m, 43 Ib-ft)
95 N.m (9.5 kg-m, 69 Ib-ft)
12 x 1.25 mm
8×1.25 mm
22 N.m (2.2 kg-m, 16 Ib-ft)
PARKING BRAKE CABLE
HOLDERS
28. Install the transmission mount and two trans-
mission housing mounting bolts.
29. Install the starter motor and connect the starter
motor cables.
NOTE: When installing the starter motor cable,
make sure that the crimped side of the ring ter-
minals facing out (see section 23).
30. Install the transmission ground cable and jumper
connector, and connect the back-up light switch,
neutral position switch and vehicle speed sensor
(VSS) connectors.
Corrosion resistant bolt/nut TRANSMISSION HOUSING
MOUNTING BOLTS
12 x 1.25mm
65 N.m (6.5 kg-m, 46 Ib-ft)
BACK-UP LIGHT
SWITCH
CONNECTOR
WIRE
HARNESS
HOLDER
NEUTRAL
POSITION
SWITCH
CONNECTOR
STARTER
MOTOR
CABLES
12 x 1.25 mm
95 N.m (9.5 kg-m, 69 Ib-ft)
12 x 1.25 mm
75 N.m (7.5 kg-m, 54 Ib-ft)
12 x 1.25 mm
75 N.m (7.5 kg-m, 54 Ib-ft)
TRANSMISSION
GROUND CABLE
TRANSMISSION MOUNTING
BOLTS
10 x 1.25 mm
60 N.m (6.0 kg-m, 43 Ib-ft)
JUMPER
CONNECTOR
VSS
CONNECTOR
CONTROL BOX
31. Install the control box and connect the control box
connectors.
32. Install the air cleaner assembly.
33. Install the strut bar.
34. Refill the transmission with oil (see page 13-3).
35. Connect the battery positive (+) and negative (-)
cables to the battery.
36. Inspect the rear camber (see section 18).
37. Check the clutch operation.
38. Shift the transmission and check for smooth
operation.
TRANSMISSION MOUNTING
BOLT