Special tool (s)
Power unit jack assembly HTJ1200-02 | |
Gear selector adjustment tool 308-561 |
Installation
NOTE: If a new transmission is being installed, the shift lever mounting bolts must first be installed on the transmission to cut the threads. Failure to follow this instruction will result in increased difficulty installing the shift lever to the transmission.
1.
NOTE: Make sure the stud is inserted from left to right when viewed from the back of the transmission.
Install the shift fork.
- Install the pin.
- Tighten the nut with a tightening torque of 12 Nm.
2. Install the clutch slave cylinder.
- Tighten the bolts (tightening torque 11 Nm).
- Install the connecting tube.
- Install the connecting tube retainer.
3. Establish the switch of lanterns of a backing. Tighten (tightening torque 20 Nm).
4. Install the seal.
5.
NOTE: Apply anti-seize lubricant to the splines.
NOTE: Make sure the yoke fits between the tabs on the extension shaft seal cover and that it is cut flush with the tabs.
Install the transmission extension shaft.
- Install the cover.
- Install clamp.
6. Establish the case of the console of a transmission. Tighten the bolts (tightening torque 25 Nm).
7.
NOTE: Apply STC 50552 sealant to the bolt threads.
Install the transfer box with an assistant.
- Tighten the bolts (tightening torque 45 Nm).
- Tighten the nuts to 45 Nm.
8.
NOTE: This step should only be performed when installing a new transmission.
Screw in the shift housing mounting bolts to cut a new thread. Turn out bolts.
9.
CAUTION: Be careful when docking the gearbox to the clutch.
Install the gearbox and transfer case.
10.
NOTE: Before installing, install the rubber gasket on the shift lever housing.
Install the gear shift housing.
11.
NOTE: From under the car.
Screw in three accessible bolts of fastening of the case of the gear change mechanism and tighten only by force of a hand.
12. Attach the gearbox to the engine.
13. Screw bolts of fastening of forward section of a crankcase. Tighten to 40 Nm.
14. Install the right transfer case support bracket.
- Tighten the nut to 48 Nm.
- Tighten the bolts to 85 Nm.
15. Install the left support and transmission support bracket.
- Tighten the nut to 48 Nm.
- Tighten the bolts to 85 Nm.
16. Remove the HTJ1200-02 special tool from the gearbox and transfer case.
17. Connect the hose to the clutch slave cylinder.
- Remove the plugs from the holes.
- Install a new clutch slave cylinder hose o-ring.
- Install the clutch slave cylinder tube clamp.
18. Install and fully tighten the clutch slave cylinder hose support bracket nut and bolt.
- Remove the pipe clamp from the clutch slave cylinder hose.
- Tighten the bolt to 25 Nm.
19. Fix a plait of electroconducting on a transmission.
20. Move the wiring harness and screw the nut and screw the bolt of the gearbox wiring harness bracket. Tighten to 47 Nm.
21. Install the transfer case breather line.
- Install new sealing washers on the transfer case breather pipe bolt.
- Screw in the bolt.
- Tighten to 15 Nm.
22. Attach an electric socket of the gauge of blocking of differential. Attach the electrical connector to the bracket.
23. Move and secure the high-low range detection switch electrical connector to the transfer case. Attach the electrical connector to the bracket.
24. Screw in a bolt of fastening of the right wires of grounding of a distributing box. Tighten to 12 Nm.
25. Screw a nut of fastening of the left wire of grounding of a distributing box. Tighten to 45 Nm.
26. Dock the electrical connector of the electronic speedometer drive on the transfer case.
27. Install the parking brake assembly.
- Screw in four bolts.
- Tighten to 73 Nm.
28. Install the brake drum drum. Screw in the screw.
29.
NOTE: Move to the position marked during removal.
Move and secure the rear driveshaft to the transfer case.
- Release the propeller shaft from the chassis.
- Screw in the bolts securing the rear section of the cardan shaft to the transfer case.
- Tighten to 47 Nm.
30. Install and secure the intermediate pipe and muffler.
- Install a new gasket.
- Screw nuts of fastening of a back pipe with the muffler to an intermediate pipe.
- Tighten to 25 Nm.
31. Install the catalytic converter.
- Clean the mating surfaces of the catalytic converter.
- Install, but do not tighten, the two catalytic converter support bracket bolts.
32. Fix the catalytic converter. Install, but do not tighten, the catalytic converter to intermediate pipe nuts.
33. Lower the car.
34. Install four new catalytic converter mounting studs.
35. Install four new nuts. Tighten to 45 Nm.
36. Install the turbocharger heat shield. Tighten to 10 Nm.
37. Close the hood.
38. Tighten to 30 Nm.
39. Tighten to 30 Nm.
40. Install the front driveshaft.
For more information, see chapter: Front propeller shaft (205-01 Cardan shaft, Removal and installation).
41.
NOTE: Left side shown, right side similar.
Install the chassis cross member. Tighten to 85 Nm.
42. Open the front door.
43. Dock an electric socket of the switch of lanterns of a backing.
44.
NOTE: Move the transmission to third gear.
NOTE: Align the shift lever ball bushing and selector yoke before installing the special tool.
Install the shift lever. Install special tool 308561 on the shift lever.
45. Tighten four bolts of fastening of the case of the mechanism of a gear change. Tighten to 25 Nm.
46. Remove special tool 308-561 from shift lever.
47. Install a new differential lock pivot nut. Tighten to 25 Nm.
48. Install the high-low range select lever to the transmission. Tighten to 7 Nm.
49. Install foam padding.
50. Install the upper shift lever.
51. Establish a cover of the lever of a gear change.
- Attach the shift lever boot to the transmission tunnel.
- Attach the shift lever boot to the high-low range select lever.
52. Install the carpet on the transmission cover panel.
53. Install the floor console assembly.
For more information, see the chapter: Floor Console (501-12 Instrument panel and console, Removal and installation).
54. Connect the wire "masses" to the battery.
For more information, see the chapter: Disconnecting and connecting the battery (414-01 Battery, Battery Mount and Wires, General Procedures).
55. Install the battery cover.
56. Install the front seat cushion assembly.
For more information, see chapter: Front seat cushion (501-10 Seat, Removal and installation).
57. Raise the car on a lift.
58.
NOTE: Make sure the link is fully engaged on the ball joint and not on the foam washer.
Install the high-low selector linkage ball joint on the transfer case.
59. Release the air from the hydraulic clutch.
For more information, see the chapter: Bleeding the clutch system (308-00 Manual Transmission / Transaxle Transmission and Clutch - General Information, General Procedures).
60. Lower the car.
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