1. Replace the differential side retainer oil seal. 
NOTE:
When a new oil seal has been installed, replacement is not required.
2. Install the transmission cushion rubber to the transmission assembly, and tighten bolt (A).
3. Install the transmission cushion rubber to the center crossmember, and tighten the nut (B).
Tightening torque:
Bolt (A)
35 N·m (3.6 kgf-m, 25.8 ft-lb)
Nut (B)
35 N·m (3.6 kgf-m, 25.8 ft-lb)
4. Tap the transmission hanger in the rear side of transmission with a rubber hammer to bend it until it is in close contact with the transmission case.
CAUTION:
Do not apply excessive load or impact to the transmission case.
5. Install the transmission onto the engine.
(1) Lift up the transmission gradually using a transmission jack.
(2) Engage at the spline section.
NOTE:
Be careful not to hit the main shaft against the clutch housing cover.
6. While raising the transmission jack, loosen the turnbuckle of the ST, and set the engine unit to the original position.
7. Install the front crossmember and rear crossmember.
Tightening torque:
T1: 70 N·m (7.1 kgf-m, 51.6 ft-lb)
T2: 140 N·m (14.3 kgf-m, 103.3 ft-lb)
8. Take out the transmission jack.
9. Tighten the bolts and nuts which hold the lower side of transmission to the engine.
NOTE:
Tighten together with the transmission case cover bracket.
Tightening torque:
50 N·m (5.1 kgf-m, 36.9 ft-lb)
|
(A) |
Sections tightened together with the transmission case cover bracket |
10. Connect the transmission to the engine.
(1) Install the starter.
(2) Tighten the bolts which hold the upper side of the transmission to the engine.
Tightening torque:
50 N·m (5.1 kgf-m, 36.9 ft-lb)
11. Remove the ST.
12. Install the pitching stopper.
Tightening torque:
T1: 50 N·m (5.1 kgf-m, 36.9 ft-lb)
T2: 58 N·m (5.9 kgf-m, 42.8 ft-lb)
13. Lift up the vehicle.
14. Attach the ST to the transmission.
| ST 28399SA010 | OIL SEAL PROTECTOR |
15. Insert the front drive shaft to the transmission.
16. Insert the front arm ball joint into the housing lower part, and tighten the mounting bolt.
Tightening torque:
50 N·m (5.1 kgf-m, 36.9 ft-lb)
|
(A) |
Front arm |
|
(B) |
Ball joint |
|
(C) |
Stabilizer link |
17. Attach the stabilizer link to the front arm.
Tightening torque:
45 N·m (4.6 kgf-m, 33.2 ft-lb)
18. Install the MT gear shift cable and MT gear select cable to MT gear shift lever.
CAUTION:
• Do not bend MT gear shift cable and MT gear select cable at a sharp angle.
• If the MT gear select cable is removed from the selector lever COMPL side of transmission, always replace with new MT gear select cable.
19. Install the propeller shaft.
20. Install the heat shield cover.
21. Install the transmission under cover.
22. Install the hanger bracket to the transmission.
23. Install the exhaust pipe (front).
24. Lower the vehicle.
25. Install the engine hanger and the intake manifold stay.
Tightening torque:
16 N·m (1.6 kgf-m, 11.8 ft-lb)
Engine hanger
Intake manifold stay
26. Attach five bolts securing the water pipe, and install the harness.
Tightening torque:
6.4 N·m (0.7 kgf-m, 4.7 ft-lb)
Upper side of the engine
Rear side of #4 cylinder
Lower left side of the engine
27. Install the throttle body.
28. Install the operating cylinder.
Tightening torque:
37 N·m (3.8 kgf-m, 27.3 ft-lb)
29. Connect the following connectors.
(1) Transmission ground cable
Tightening torque:
13 N·m (1.3 kgf-m, 9.6 ft-lb)
(2) Neutral position switch connector (Brown)
(3) Back-up light switch connector (Gray)
30. Fill transmission gear oil through the transmission oil level gauge hole.
31. Install the intercooler stay and the intercooler.
32. Install the collector cover.
33. Connect the battery ground terminal.
34. Remove the vehicle from lift arms.