Manual Transmission Assembly: Installation

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

Install the release bearing & lever. Refer to CLUTCH SYSTEM>Release Bearing and Lever>INSTALLATION .
Replace the differential side retainer oil seal with a new part. Refer to MANUAL TRANSMISSION AND DIFFERENTIAL (6MT)>DIFFERENTIAL SIDE RETAINER OIL SEAL>REPLACEMENT .
CAUTION: Be sure to replace the oil seal after removing the front drive shaft.

NOTE: When a new oil seal has been installed, replacement is not required.
Strike and bend the transmission hanger of transmission rear with a rubber hammer etc. so that it gets in contact with the transmission case.
CAUTION: Do not apply excessive load or impact to the transmission case.

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Install the transmission cushion rubber to the transmission, and tighten the bolt (A).
Install the transmission cushion rubber to the center crossmember, and temporarily tighten the nut (B).
Tightening torque:

Bolt (A)

35 N.m (3.6 kgf-m, 25.8 ft-lb)

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Install the transmission assembly onto the engine.
1. Lift up the transmission gradually using a transmission jack.
2. Engage at the spline section.
  CAUTION: Be careful not to hit the main shaft against the clutch cover.
While raising the transmission jack, loosen the turnbuckle of the ST (ENGINE SUPPORT), and set the engine unit to the original position.
Install the front crossmember and rear crossmember.
Tighten the transmission cushion rubber mounting nut.
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)

T3: 35 N.m (3.6 kgf-m, 25.8 ft-lb)

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Take out the transmission jack.
Tighten the bolts and nuts which hold the lower side of transmission to the engine.
Tightening torque:

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

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Lower the vehicle.
Install the starter. Refer to STARTING/CHARGING SYSTEMS (H4DO (EXCEPT FOR HEV))>STARTER>INSTALLATION .
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)

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Remove ST (ENGINE SUPPORT BRACKET and ST ENGINE SUPPORT).
Install the engine ground terminals.
Tightening torque:

19 N.m (1.9 kgf-m, 14.0 ft-lb)
Install the engine harness stay and MT docking connector together as a unit.
Tightening torque:

19 N.m (1.9 kgf-m, 14.0 ft-lb)

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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)

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Lift up the vehicle.
Set the ST (OIL SEAL PROTECTOR) to the differential side retainer.
Replace the circlip of the front drive shaft with a new part.
Install the front drive shaft and remove ST.
Preparation tool:

ST: OIL SEAL PROTECTOR (28399SA010)

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Insert the front arm ball joint and tighten the mounting bolt.
CAUTION:
- Do not apply grease to the tapered portion of ball stud.
- Before tightening, make sure the lower side of front axle housing and stepped section of ball joint are in contact.
- Be careful not to damage the boot of the joint.
Tightening torque:

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

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Replace the flange nut with a new part, and install the stabilizer link.
Tightening torque:

60 N.m (6.1 kgf-m, 44.3 ft-lb)

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Install the MT gear shift cable and MT gear select cable to MT gear shift lever. Refer to CONTROL SYSTEMS>MT GEAR SHIFT LEVER>INSTALLATION .
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 on the transmission side, replace with new MT gear select cable.
- Do not apply excessive load while holding the part (A).
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Install the propeller shaft. Refer to DRIVE SHAFT SYSTEM>PROPELLER SHAFT>INSTALLATION .
Install the hanger bracket.
Tightening torque:

23 N.m (2.3 kgf-m, 17.0 ft-lb)

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Install the center exhaust cover.
Tightening torque:

18 N.m (1.8 kgf-m, 13.3 ft-lb)

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Install the rear exhaust pipe. Refer to EXHAUST (H4DO (EXCEPT FOR HEV))>REAR EXHAUST PIPE>INSTALLATION .
Install the front exhaust pipe. Refer to EXHAUST (H4DO (EXCEPT FOR HEV))>FRONT EXHAUST PIPE>INSTALLATION .
Install the crossmember support - rear.
Tightening torque:

70 N.m (7.1 kgf-m, 51.6 ft-lb)

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Lower the vehicle.
Install the operating cylinder.
Tightening torque:

37 N.m (3.8 kgf-m, 27.3 ft-lb)

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Install the engine hanger rear.
Tightening torque:

21 N.m (2.1 kgf-m, 15.5 ft-lb)

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Install the transmission radio ground cord terminal.
Tightening torque:

32.3 N.m (3.3 kgf-m, 23.8 ft-lb)

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Connect the air breather hose.

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Install the coupling harness.

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Pour in transmission gear oil and check the oil level. Refer to MANUAL TRANSMISSION AND DIFFERENTIAL (6MT)>TRANSMISSION GEAR OIL .
Install the air intake boot. Refer to INTAKE (INDUCTION) (H4DO (EXCEPT FOR HEV))>AIR INTAKE BOOT>INSTALLATION .
Install the front tires. Refer to WHEEL AND TIRE SYSTEM>TIRE AND WHEEL>INSTALLATION .
Connect the ground terminal to 12V engine restart battery sensor. Refer to REPAIR CONTENTS>REPAIR CONTENTS>NOTE>BATTERY .