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.
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)
TRANSMISSION
JACK
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 (6.0 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)
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)
COTTER PIN
Replace.
SLAVE CYLINDER
6 x 1.0 mm
12 N-m (1.2 kg-m,
9 Ib-ft)
CHANGE
WIRE
BRACKET
LOWER
COVER
8 x 1.25 mm 6 x 1.0 mm
26 N-m (2.6 kg-m, 19 Ib-ft) 12 N-m (1.2 kg-m, 9 Ib-ft)
UPPER CONTROL ARM MOUNTING BOLT
10 x 1.25 mm
60 N-m (6.0 kg-m, 43 Ib-ft)
(P/N 08798-9002)
Corrosion resistant bolt/nut
UPPER COVER
12. Install a new set ring on the end of the left driveshaft and intermediate shaft.
13. Install the left driveshaft (see section 16).
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.
15. 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
SELF-LOCKING NUT
Replace
12 x 1.25 mm
95 N-m (9.5 kg-m, 69 Ib-ft)
DAMPER
FORK BOLT
SELF-LOCKING NUT
Replace.
12 x 1.25 mm
85 N-m (8.5 kg-m, 61 Ib-ft)
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)
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
SET RING
Replace.
SELF-LOCKING NUT
Replace.
14 x 1.5 mm
125 N-m (12.5 kg-m, 90 Ib-ft)
6 x 1.0 mm
10 N-m (1.0 kg-m, 7 Ib-ft)
HEAT COVER
8 x 1.25 mm
22 N-m
(2.2 kg-m, 16 Ib-ft)
INTERMEDIATE SHAFT
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.
SUPPORT BASE
Corrosion resistant bolt/nut
ADJUSTING ADJUSTING
BOLT CAM
Transmission Assembly
Installation
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
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)
SELF-LOCKING NUT
Replace.
12 x 1.25 mm
85 N-m (8.5 kg-m, 61 Ib-ft) DAMPER
FORK BOLT
TOE CONTROL ARM
SELF-LOCKING NUT
Replace.
14 x 1.5 mm
125 N-m (12.5 kg-m, 90 Ib-ft)
ADJUSTING CAM
ADJUSTING BOLT
25. Install the front exhaust pipe A.
26. Install the rear beam rod.
27. Install the parking brake cable holders on the rear beam rod.
SELF-LOCKING NUT
Replace
12 x 1.25 mm
95 N-m (9.5 kg-m, 69 Ib-ft)
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)
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
PARKING BRAKE CABLE
HOLDERS
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)
12 x 1.25 mm
95 N-m (9.5 kg-m, 69 Ib-ft)
10 x 1.25 mm
60 N-m (6.0 kg-m, 43 Ib-ft)
SELF LOCKING NUT
Replace.
10 x 1.25 mm
55 N-m (5.5 kg-m, 40-lb-ft)
8 x 1.25 mm
22 N-m (2.2 kg-m, 16 Ib-ft)
28. Install the transmission mount and two transmission
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 termi-
nals facing out (see section 23).
30. Install the transmission ground cable and jumper con-
nector, and connect the back-up light switch, neu-
tral position switch, differential speed sensor, and
vehicle speed sensor (VSS) connector.
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 opera-
tion.
Corrosion resistant bolt/nut TRANSMISSION HOUSING
MOUNTING BOLTS
12 x 1.25 mm
65 N-m (6.5 kg-m, 47 Ib-ft) CONTROL BOX
BACK-UP LIGHT
SWITCH
CONNECTOR
WIRE
HARNESS
HOLDER
NEUTRAL
POSITION
SWITCH
CONNECTOR
STARTER
MOTOR
CABLES
DIFFERENTIAL
SPEED SENSOR
VSS
CONNECTOR
JUMPER
CONNECTOR
TRANSMISSION MOUNTING
BOLT
TRANSMISSION MOUNTING
BOLTS
10 x 1.25 mm
60 N-m (6.0 kg-m, 43 Ib-ft)
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