Transmission Removal and Installation

Removal and Installation from Vehicle





REMOVAL
1. Drain transmission oil.
2. Disconnect the battery cable from the negative terminal.
3. Remove the shift lever assembly.
4. Remove the LH fender protector.





5. Remove the crankshaft position sensor (POS) from M/T assembly.

CAUTION: Do not damage the sensor edge.

6. Remove the undercovers using power tool.
7. Remove the front crossmember using power tool.
8. Remove the starter motor.
9. Remove the rear propeller shaft.
10. Remove the left and right front exhaust tubes.
11. Remove the clutch operating cylinder from the transmission.
12. Support the transmission using a suitable jack.
13. Remove the nuts securing the insulator to the crossmember.
14. Remove the crossmember using power tool.

WARNING: Support the transmission using suitable jack.

15. Tilt the transmission slightly to gain clearance between the body and the transmission, then disconnect the air breather hoses.
16. Disconnect the following:
^ Back-up lamp switch connector
^ Park/neutral position (PNP) switch connector
17. Remove the wiring harness from the retainers.
18. Remove the transmission to engine bolts using power tool.
19. Separate the transmission from the engine and remove it from the vehicle.

WARNING: Support the transmission while removing it using suitable jack.

INSTALLATION
Installation is the reverse order of removal.





^ When installing the transmission to the engine, tighten the bolts to the specified torque.





CAUTION:
^ When installing be careful to avoid interference between transmission main drive gear and clutch cover.
^ After installation, check for oil leakage and oil level.
^ If flywheel is removed, align dowel pin with the smallest hole of flywheel.
^ When replacing an engine or transmission you must make sure the dowels are installed correctly during re-assembly.
^ Improper alignment caused by missing dowels may cause vibration, oil leaks or breakage of drive train components.