Manual Transmission Assembly: Installation

Install the rear cushion rubber to the transmission assembly.
Tightening torque:

35 N.m (3.6 kgf-m, 26 ft-lb)
Install the transmission onto the engine.
1. Lift-up the transmission gradually using a transmission jack.
2. Loosen the turnbuckle of ST to return the engine to its original position.
3. Engage at the spline section.
NOTE: Be careful not to hit the main shaft against the clutch housing cover.
Install the transmission rear crossmember.
Tightening torque:

T1: 75 N.m (7.6 kgf-m, 55 ft-lb)

T2: 140 N.m (14.3 kgf-m, 103 ft-lb)

Fig 1: Identifying Transmission Rear Crossmember Bolts
Take out the transmission jack.
Tighten the nuts which hold the lower side of the transmission to the engine.
Tightening torque:

50 N.m (5.1 kgf-m, 36.9 ft-lb)

Fig 2: Locating Transmission Bolts
Connect the transmission to the engine.
1. Install the starter.
  < Ref. to INSTALLATION , 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)

Fig 3: Locating Transmission Bolts
Remove the ST.

Fig 4: Identifying Engine Support Assy
Install the pitching stopper.
Tightening torque:

T1: 50 N.m (5.1 kgf-m, 37 ft-lb)

T2: 58 N.m (5.9 kgf-m, 43 ft-lb)

Fig 5: Identifying Pitching Stopper
Lift-up the vehicle.
Install the front drive shaft into the transmission.
Replace the differential side retainer oil seal. < Ref. to REPLACEMENT , Differential Side Retainer Oil Seal. >
ST 18675AA000 DIFFERENTIAL SIDE OIL SEAL INSTALLER

NOTE: Be sure to replace the differential side retainer oil seal after the removing the front drive shaft.

Fig 6: Installing Differential Side Retainer Oil Seal
Install the front drive shaft into the transmission.
ST 28399SA010 FRONT DRIVE SHAFT OIL SEAL PROTECTOR

Fig 7: Installing Front Drive Shaft Into Transmission
Install the ball joint of the lower arm.
Tightening torque:

49 N.m (5.0 kgf-m, 36 ft-lb)

Fig 8: Locating Lower Arm Ball Joint Bolt
Attach the stabilizer link to the front arm.
Tightening torque:

45 N.m (4.6 kgf-m, 33.2 ft-lb)

Fig 9: Attaching Stabilizer Link To Front Arm
Attach the gear shift rod and stay.
1. Attach the gear shift rod to the transmission.
  
  Fig 10: Attaching Gear Shift Rod And Stay
2. Attach the stay to the transmission.
Install the propeller shaft. < Ref. to INSTALLATION , Propeller Shaft. >
Install the heat shield cover. (If equipped)
Install the rear exhaust pipe and muffler.
Install the front exhaust pipe and the center exhaust pipe. (Non-turbo model)
< Ref. to INSTALLATION , Front Exhaust Pipe. >
Install the center exhaust pipe. (Turbo model)< Ref. to INSTALLATION , Center Exhaust Pipe. >
Install the operating cylinder.
Tightening torque:

37 N.m (3.8 kgf-m, 27.5 ft-lb)

Fig 11: Locating Operating Cylinder Bolts
Connect the following connectors.
1. Transmission ground cable
  Tightening torque:
  
  13 N.m (1.3 kgf-m, 9.4 ft-lb)
2. Neutral position switch connector
3. Back-up light switch connector
Fill transmission gear oil through the transmission level gauge hole.
Install the air intake chamber stay. (Non-turbo model)
Tightening torque:

16 N.m (1.6 kgf-m, 11.6 ft-lb)
Install the air intake chamber and air cleaner case. (Non-turbo model) < Ref. to INSTALLATION , Air Cleaner Case. > < Ref. to INSTALLATION , Air Intake Chamber. >
Install the intercooler. (Turbo model) < Ref. to INSTALLATION , Intercooler. >
Connect the ground cable to battery.
Take off the vehicle from lift arms.