Removal and Replacement
Manual Transmission AssemblyREMOVAL
1. Set the vehicle an a lift.
2. Disconnect the ground cable from battery.
3. Drain the transmission gear oil completely.
4. Open the front hood fully, and support with stay.
5. non-turbo - Remove the air intake duct and air cleaner case.
MT Vehicles:
6. non-turbo - Remove the air cleaner case stay.
Turbo Models - Remove intercooler.
7. Disconnect the following connectors:
1. Neutral position switch connector (A)
2. Back-up light switch connector (B)
3. Vehicle speed sensor
4. Transmission ground cable
8. Remove the starter.
non-turbo
Turbo Models
9. Remove the operating cylinder from transmission, and then hold it with wires.
10. Remove the pitching stopper.
11. Set the ST.
ST 41 O99AA020 ENGINE SUPPORT ASSY
12. Remove the bolt which holds upper side of transmission to engine.
13. Remove the front and center exhaust pipes.
14. Remove the rear exhaust pipe and muffler.
CAUTION: When removing the exhaust pipes, be careful each exhaust pipe does not drop out.
15. Remove the heat shield cover.
16. Remove the hanger bracket from right side of transmission.
17. Remove the propeller shaft.
18. Remove the gear shift rod and stay from transmission.
1. Disconnect the stay from transmission.
2. Disconnect the rod from transmission.
19. Disconnect the stabilizer link from transverse link.
20. Remove the bolt securing ball joint of transverse link to housing, and then separate transverse link from housing.
21. Pull out the front drive shaft from transmission.
1. Face the "MT" letter stamped of ST to transmission side.
ST 28399SA000 DRIVE SHAFT REMOVER
2. Insert the ST into between transmission and front drive shaft.
NOTE: Contact the protrusion part of ST to transmission case.
ST 28399SA000 DRIVE SHAFT REMOVER
3. While holding the joint portion (AAR) of front drive shaft with your hand, push the housing outside to remove from transmission.
22. Remove the nuts which hold lower side of transmission to engine.
23. Place the transmission jack under transmission.
24. Remove the transmission rear crossmember from vehicle.
25. Remove the transmission.
NOTE: Move the transmission jack toward rear until main shaft is withdrawn from clutch cover.
26. Separate the transmission assembly and rear cushion rubber.
INSTALLATION
1. Replace the differential side retainer oil seal with a new one.
2. Install the rear cushion rubber to transmission assembly.
Tightening torque: 35 Nm (3.57 kgf-m, 25.8 ft. lbs.)
3. Install the transmission onto engine.
1. Gradually raise the transmission with transmission jack.
2. Engage them at splines.
NOTE: Be careful not to strike the main shaft against clutch cover.
4. Install the transmission rear crossmember.
Tightening torque:
T1: 70 Nm (7.1 kgf-m, 51 ft. lbs.)
T2: 140 Nm (14.3 kgf-m, 103 ft. lbs.)
5. Take off the transmission jack.
6. Tighten the nuts and bolts which hold lower side of transmission to engine.
Tightening torque: 50 Nm (5.1 kgf-m, 36.9 ft. lbs.)
7. Connect the engine and transmission.
1. Install the starter.
2. Tighten the bolt which holds upper side of transmission to engine.
Tightening torque: 50 Nm (5.1 kgf-m, 36.9 ft. lbs.)
8. Remove the ST.
9. Install the pitching stopper.
Tightening torque:
T1: 50 Nm (5.1 kgf-m, 37 ft. lbs.)
T2: 58 Nm (5.9 kgf-m, 43 ft. lbs.)
10. Lift-up the vehicle.
11. Install the front drive shaft into transmission.
12. Install the ball joints of lower arm into knuckle arm of housing, and tighten the installing bolts.
Tightening torque: 49 Nm (5.0 kgf-m, 36 ft. lbs.)
13. Install the stabilizer link from transverse link.
Tightening torque: 45 Nm (4.6 kgf-m, 33.2 ft. lbs.)
14. Install the gear shift rod and stay.
1. Install the gear shift rod onto transmission.
Tightening torque: 18 Nm (1.8 kgf-m, 13.0 ft. lbs.)
2. Install the stay onto transmission.
Tightening torque: 18 Nm (1.8 kgf-m, 13.0 ft. lbs.)
15. Install the propeller shaft.
16. Install the heat shield cover.
17. Install the hanger bracket on right side of transmission.
18. Install the rear exhaust pipe and muffler.
19. Install the front exhaust pipe and center exhaust pipe.
20. Install the under cover.
non-turbo
Turbo Models
21. Install the operating cylinder.
Tightening torque: 37 Nm (3.8 kgf-m, 27.5 ft. lbs.)
22. Connect the following connectors:
1. Transmission ground cable
Tightening torque: 13 Nm (1.3 kgf-m, 9.4 ft. lbs.)
2. Vehicle speed sensor connector
3. Neutral position switch connector
4. Back-up light switch connector
23. Install the air cleaner case stay.
24. Fill gear oil into the gauge hole.
Tightening torque: 16 Nm (1.6 kgf-m, 11.6 ft. lbs.)
25. Install the air intake chamber and duct.
26. Install intercooler(Turbo Models)
27. Connect the battery ground cable to battery.
28. Take off the vehicle from lift.