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Transmission Installation

WARNING: This page is about a different variant/trim than selected.

Special Tools Required 

NOTE: Use fender covers to avoid damaging painted surfaces.
  1. Make sure the two dowel pins (A) are installed in the clutch housing.
    Fig 1: Identifying Dowel Pins
    G05490985
  2. Install the release fork, the release bearing, and the boot (see step 4 on RELEASE BEARING REPLACEMENT ).
  3. Check that the mount bracket collars (A) are installed in the transmission, then install the front transmission lower mount (B) and rear transmission lower mount (C).
    Fig 2: Mount Bracket Collars And Transmission Lower Mounts w/Torque Specs.
    G05490986
  4. Place the transmission on the transmission jack, and raise it to the engine level.
  5. Install the four lower transmission mounting bolts.
    Fig 3: Lower Transmission Mounting Bolts w/Torque Specs.
    G05490987
  6. Install the clutch cover.
    Fig 4: Clutch Cover w/Torque Specs.
    G05490988
  7. Install the rear engine mount upper bracket.
    Fig 5: Rear Engine Mount Upper Bracket w/Torque Specs.
    G05490989
  8. Install the rear engine mount (A), rear engine mount upper mounting bolt (B), and shift cable bracket (C).
    Fig 6: Rear Engine Mount Upper Mounting Bolt And Shift Cable Bracket w/Torque Specs.
    G05490990
  9. Install the front engine mount upper bracket.
    Fig 7: Front Engine Mount Upper Bracket w/Torque Spec.
    G05490991
  10. Support the subframe with the subframe adapter and a jack.
    Fig 8: Supporting Subframe With Subframe Adapter And Jack
    G05490992
  11. Install the front suspension subframe (A) and front suspension subframe stiffeners (B).
    Fig 9: Front Suspension Subframe And Front Suspension Subframe Stiffeners w/Torque Specs.
    G05490993
  12. Align the reference mark (A) you made with edge (B) of both rear stiffeners (C), and tighten the rear subframe mounting bolts, then the front bolts, and tighten the stiffener bolts to the specified torque.
    Fig 10: Identifying Reference Mark At Both Ends Of Subframe
    G05490994
  13. Install the middle subframe mounting bracket.
    Fig 11: Middle Subframe Mounting Bracket w/Torque Specs.
    G05490995
  14. Install the lower transmission mount mounting nuts.
    Fig 12: Lower Transmission Mount Mounting Nuts w/Torque Spec.
    G05490996
  15. Install the rear engine mount lower bracket mounting bolts.
    Fig 13: Rear Engine Mount Lower Bracket Mounting Bolts w/Torque Spec.
    G05490997
  16. Install the intermediate shaft (see INTERMEDIATE SHAFT INSTALLATION ).
  17. Install the driveshaft inboard joint (see DRIVESHAFT INSTALLATION ).
  18. Connect the knuckle onto the lower arm (see step 7 on DRIVESHAFT INSTALLATION ).
  19. Install the damper fork (see step 9 on DRIVESHAFT INSTALLATION ).
  20. Connect the front stabilizer (see step 11 on DRIVESHAFT INSTALLATION ).
  21. Install exhaust pipe A with new gaskets (B).
    Fig 14: Exhaust Pipe And Gaskets w/Torque Specs.
    G05490998
  22. Connect the power steering pressure switch connector.
    Fig 15: Identifying Power Steering Pressure Switch Connector
    G05490999
  23. Connect the return line to the power steering fluid reservoir.
  24. Connect the tie-rod ball joint (see step 24 on STEERING GEARBOX INSTALLATION ).
  25. Install the splash shield.
    Fig 16: Identifying Splash Shield
    G05491000
  26. Refill the transmission with the recommended transmission fluid (see TRANSMISSION FLUID INSPECTION AND REPLACEMENT  ).
  27. Install the front wheels, and set them in the straight ahead position.
  28. Lower the vehicle on the lift.
  29. Connect the steering joint to the steering gearbox pinion shaft (A) by aligning the reference mark (B) you made, and remove the wire (C) from the joint yoke (D).
    Fig 17: Steering Gearbox Pinion Shaft, Wire, Joint Yoke & Torque Spec.
    G05491001
  30. Install the steering joint cover (E).
  31. Install the steering wheel (see STEERING WHEEL INSTALLATION ).
  32. Check that the mount bracket collars (A) are installed in the transmission, then install the transmission mount bracket (B) and ground cable (C).
    Fig 18: Mount Bracket Collars, Transmission Mount Bracket, Ground Cable & Torque Specs.
    G05491002
  33. Remove the engine support hanger and engine hanger adapter from the engine.
  34. Install the power steering pump outlet line (A) with a new O-ring (B) to the power steering pump (C), and secure the hose clamp (D) with the bolt.
    Fig 19: Power Steering Pump, Hose Clamp, Return Hose, Power Steering Fluid Reservoir& Torque Specs.
    G05491003
  35. Connect the return hose (E) to the power steering fluid reservoir (F), then secure the hose with the clamp (G).
  36. Install the two upper transmission mounting bolts.
    Fig 20: Upper Transmission Mounting Bolts w/Torque Spec.
    G05491004
  37. Install the rear engine mount stop.
    Fig 21: Rear Engine Mount Stop w/Torque Spec.
    G05491005
  38. Install the front engine mount mounting bolt (A) and front engine mount stop (B).
    Fig 22: Engine Mount Mounting Bolt, Front Engine Mount Stop & Torque Specs.
    G05491006
  39. Install the bracket (A), then connect the secondary heated oxygen sensor (secondary HO2S) connector (B).
    Fig 23: Bracket And Secondary Heated Oxygen Sensor Connector w/Torque Spec.
    G05491007
  40. Connect the reverse lockout solenoid connector (A), back-up light switch connector (B), and output shaft (countershaft) speed sensor connector (C).
    Fig 24: Identifying Reverse Lockout Solenoid Connector And Back-Up Light Switch Connector
    G05491008
  41. Install the cable bracket (A) and cables (B).
    Fig 25: Cable Bracket, Cables & Torque Spec.
    G05491009
  42. Apply a light coat of super high temp urea grease (P/N 08798-9002) to the cable ends, and install new cotter pins (C)
  43. Apply super high temp urea grease (P/N 08798-9002) to the end of the slave cylinder rod. Install the slave cylinder. Be careful not to bend the clutch line.
    Fig 26: Grease Applying Area & Torque Specs.
    G05491010
  44. Install the battery base (see step 44 on ENGINE INSTALLATION ).
  45. Install the air cleaner assembly (see AIR CLEANER REMOVAL/INSTALLATION ).
  46. Remove the steering wheel (see STEERING WHEEL REMOVAL ).
  47. Center the cable reel and reinstall the steering wheel (see STEERING WHEEL INSTALLATION ).
  48. Install the battery. Clean the battery posts and cable terminals, connect the positive cable to the battery, then connect the negative cable, and apply multipurpose grease to prevent corrosion.
  49. Fill the power steering fluid reservoir with fluid to the upper level line.
  50. Start the engine, turn the steering wheel from lock-to-lock several times to bleed air from the power steering system.
  51. Recheck the fluid level, and refill if necessary.
  52. Check the front wheel alignment (see WHEEL ALIGNMENT ).
  53. Test-drive the vehicle.
  54. Check the shift lever and the clutch operation.
  55. Enter the anti-theft codes for the audio system and the navigation system (if equipped), then enter the audio presets.
  56. Set the clock (on vehicles without navigation).
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