Installation of Transmission
1. INSTALL O-RING
Place a new O-ring in position on the transaxle case groove.
2. INSTALL TRANSMISSION CASE GASKET
Place a new gasket in position on the transaxle case.
3. APPLY MOLYBDENUM DISULPHIDE LITHIUM BASE GREASE (NLGI NO. 2) OR MP GREASE TO INPUT SHAFT
a. Apply molybdenum disulphide lithium base grease to the input shaft spline.
b. Apply MP grease to the input shaft end.
4. ALIGN TRANSMISSION AT INSTALLATION POSITION
5. CONNECT TRANSMISSION TO DIFFERENTIAL CARRIER
Align the splines of the sleeve yoke and differential drive pinion.
6. INSTALL INPUT SHAFT
a. Align the splines of the input shaft and clutch disc.
b. Insert the input shaft into transmission case.
7. INSTALL TRANSMISSION CASE COVER
Place the case cover together with a new gasket in position on the transmission case.
8. INSTALL TRANSMISSION MOUNT BOLTS AND NUTS
Torque: 250 kg-cm (18 ft-lb, 25 N.m)
9. INSTALL INPUT SHAFT MOUNT BOLTS (A)
Apply liquid sealer on the threads and under the bolt heads.
Sealant: Part No. 08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent
Torque: 250 kg-cm (18 ft-lb, 25 N.m)
10. INSTALL REAR SUPPORT MEMBER
Torque: 970 kg-cm (70 ft-lb, 95 N.m)
11. CONNECT SPEEDOMETER CABLE
12. CONNECT FOLLOWING CONNECTOR:
a. Back-up light connector.
b. 4WD indicator switch connector.
c. Extra low gear (EL) indicator switch connector.
13. CONNECT SELECTING ROD
Torque: 240 kg-cm (17 ft-lb, 24 N.m)
14. INSTALL EXHAUST FRONT PIPE
Torque the two nuts holding the front pipe to the exhaust manifold.
Torque: 630 kg-cm (46 ft-lb, 62 N.m)
15. (Fed.)
INSTALL CONVERTER AIR INLET PIPE
16. INSTALL PROPELLER SHAFT
Torque: 430 kg-cm (31 ft-lb, 42 N.m)
17. FILL WITH GEAR OIL
a. Loosen the transmission case rear drain plug by eight turns.
b. Add new oil until it begins to run out of the filler holes.
Transmission and differential oil:
Oil grade: API GL-4 or GL-5
Viscosity: SAE 75W-90 or 80W-90
Oil capacity (transmission and differential):
3.9 liters (4.1 US qts, 3.4 lmp.qts)
NOTE: Always fill from the transfer adaptor filler plug.
c. Torque the drain and filler plugs.
Torque: 410 kg-cm (30 ft-lb, 40 N.m)
18. INSTALL SHIFT LEVER
19. INSTALL CONSOLE BOX
20. CONNECT CABLE TO NEGATIVE TERMINAL OF BATTERY
21. PERFORM ROAD TEST
Check for abnormal noise or operation.