M/T Assembly Installation
Special Tools Required

Engine support hanger
 AAR-T1256-J00
*
*: This special tool is available from Snap-on Tools    International, LLC.
NOTE: Use fender covers to avoid damaging painted surfaces.
  1. Loosen the upper torque rod mounting bolt (A).
  1. Make sure two dowel pins (A) are installed prescribed hole on the engine block as shown.
  1. Place the transmission on the transmission jack, and raise it to engine level.
  1. Align the transmission mainshaft and the clutch pressure plate, then move the transmission inward until there is no gap between the transmission housing and the engine block.
  1. Install the lower transmission mounting bolts (A).
Front side
Rear side
  1. Install the intercooler pipe (A).
  1. Support the front suspension subframe with a jack.
    NOTE:
    • Be sure that the pinion shaft grommet is in place securely. Check whether the pinion shaft grommet is not turning up. Incorrect installation can cause leakage of water, mud, noise.
    • Take care not to damage the lower arm ball joint boot with the edge of the knuckle, etc.
    • Be careful as much as possible not damage painted surface.
  1. Install the front suspension subframe with the steering gearbox. Loosely install the new subframe mounting bolts.
  1. Insert the subframe alignment pin through the positioning hole (A) on the subframe (B), and into the positioning hole (C) on the body, then loosely tighten the subframe right-rear mounting bolts.
  1. Insert the subframe alignment pin through the positioning hole on the subframe, and into the positioning hole on the body, then loosely tighten the subframe left-rear mounting bolts.
  1. Tighten the subframe mounting bolts to the specified torque.
  1. Check that the positioning holes on the subframe, and the positioning holes on the body are aligned using the subframe alignment pin.
  1. Install the new lower torque rod mounting bolts (A).
  1. Install the exhaust pipe mounting rubber (A) on the front suspension subframe (B).
  1. LHD model: Remove the vinyl tape, and connect the torque sensor 4P connector (A) and motor-angle sensor 6P connector (B) to the steering gearbox, then install them to the harness clamp bracket (C). Make sure to push these connectors until you hear a click so that the connectors are secured.
  1. RHD model: Remove the vinyl tape, then connect the torque sensor 4P connector (A), motor-angle sensor 6P connector (B), motor 1P connector (C), and motor 2P connector (D) to the steering gearbox. Make sure to push these connectors until you hear a click so that the connectors are secured.
  1. LHD model: Remove the vinyl tape, then connect the motor 1P connector (A) and motor 2P connector (B) to the steering gearbox. Make sure to push these connectors until you hear a click so that the connectors are secured.
  1. Wipe off any grease contamination from the lower arm ball joint tapered section and the threads. Then reconnect the lower arm to the knuckle.
  1. Wipe off any grease contamination from the ball joint tapered section and the threads. Reconnect the tie-rod ends (A) to the steering knuckles. Install the 12 mm nut (B) and tighten it.
  1. Install the new cotter pin (C) and bend it as shown.
  1. Lower the vehicle on a lift.
  1. Install the stud bolts (A).
  1. Install the new transmission mount bolt (A), new nuts (B) and the ground cable bolt (C).
  1. Raise the vehicle on the lift.
  1. Loosen and retighten the lower torque rod mounting bolt.
  1. Lower the vehicle on the lift.
  1. Tighten the upper torque rod mounting bolt.
  1. Install the transmission upper mounting bolts (A).
  1. Loosen the wing nut (A). Remove the hook (B) and the engine support hanger (C) from the vehicle.
  1. Install the harness cover (A) and the harness holder (B).
  1. Install the cable bracket.
  1. Apply a light coat of silicone grease to the cable ends (A), and connect the cable end to the change lever assembly (B), then install the new cable clips (C) and the lock pins (D). Do not bend or damage the shift cables.
    NOTE: Make sure not to get any silicone grease on the terminal part of the connectors and switches, especially if you have silicone grease on your hands or gloves.
  1. Install the harness bracket (E).
  1. Install the air cleaner housing stay A and the air cleaner housing stay B.
  1. Apply a light coat of molybdenum grease to the end of the cylinder rod (A).
  1. Install the clutch hose bracket (B), then install the slave cylinder (C). Do not bent or damage the clutch line.
  1. Connect the back-up light switch connector (A), countershaft speed sensor connector (B) and reverse lockout solenoid connector (C).
  1. Install the battery base (A).
  1. Install the battery base (B).
  1. Connect the steering joint (A) in the their original positions on the pinion shaft (B) by aligning the marks (C). Install the steering joint bolt (D).
  1. Pull the steering joint toward the column and be sure that it does not come off the pinion shaft. Install the steering cover (E).
  1. Install the battery. Connect the positive cable first, then the negative cable to the battery.
  1. Check the shift lever and the clutch operation.
  1. Test-drive the vehicle.
  1. Enter the anti-theft codes for the audio or the navigation system, then enter the customer's audio presets, and set the clock.