M/T Assembly Installation
Special Tools Required
  1. Loosen the upper torque rod mounting bolt(A).
  1. Check that the two dowel pins are installed in the clutch housing.
  1. Apply urea grease UM264 (P/N 41211-PY5-305) to the release fork (A) and the release bearing (B). Install the release fork and the release bearing.
  1. Place the transmission on the transmission jack, and raise it to the engine level.
  1. Push the transmission towards engine until mainshaft engages with the spline of pressure plate.
  1. Install the lower transmission mounting bolts.
  1. Install the intercooler pipe.
  1. Support the 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 special tool through the positioning hole (A) on the subframe, and into the positioning hole (B) on the body, then loosely tighten the subframe right rear mounting bolt.
  1. Insert the special tool through the positioning hole on the subframe, and into the positioning hole on the body, then loosely tighten the subframe left rear mounting bolt.
  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 special tool.
  1. Install the lower torque rod mounting bolts.
  1. Install the exhaust pipe mounting rubber (A) on the front suspension subframe (B).
  1. Connect the EPS connectors.
  1. Wipe off any grease contamination from the ball joint tapered section and threads. Then reconnect the tie-rod end (A) to the knuckle arms.
  1. Install the tie-rod end ball joint nut and tighten it to the specified torque. Then install the new cotter pin (B) and bend it as shown (C) or (D).
  1. Install the stud bolts.
  1. Install the transmission mount bolt (A), nuts (B) and the ground cable bolt(C).
  1. Loosen and retighten the lower torque rod mounting bolt.
  1. Install the engine undercover.
  1. Tighten the upper torque rod mounting bolt.
  1. Install the transmission upper mounting bolts (A).
  1. Remove the chain hoist and engine hanger.
  1. Install the harness cover (A) and the harness holder (B).
  1. Install the cable bracket.
  1. Install the cables (A) onto the cable bracket and apply a light coat of urea grease UM264 (P/N 41211-PY5-305) to the cable ends (B).
  1. Coat the surface of the wire end rubber with silicone grease then connect the cables, install the new cotter pins (C) and the new change wire plate (D). Install the harness bracket (E).
  1. Install the air cleaner housing stay A and the air cleaner housing stay B.
  1. Apply urea grease UM264 (P/N 41211-PY5-305) to the end of the cylinder rod. Install the slave cylinder. Be careful not to bend 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 towerd 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. Shift into the 5th gear. Make sure the transmission does not shift direct into the reverse gear. (Then return to Neutral position, and enable to shift into reverse gear.)
  1. Enter the anti-theft codes for the radio and navigation system, then enter the customer's radio station presets.
  1. Test-drive the vehicle.