Manual Transmission Installation

Manual Transmission Installation

Special Tools Required

- Engine support hanger , A and Reds AAR-T1256*
- Engine hanger/adapter VSB02C000015*
- Front subframe adapter VSB02C000016*
*: These special tools are available through the Honda Tool and Equipment Program.

1. Make sure the two dowel pins (A) are installed in the clutch housing.

2. Check the release bearing, and reinstall the release bearing and the release fork with the appropriate grease. Service and Repair






3. Install the rear transmission mount bracket (A) and the rear transmission mount (B).

4. Place the transmission on a transmission jack, and raise it to the engine level.

5. 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.

4WD





2WD





6. Install the four lower transmission mounting bolts.






7. Install the front engine mount (A) with new bolts (B).






8. Install the clutch cover (A).






9. Lift and support the front subframe (A) with the front subframe adapter (VSB02C000016) and a jack(B).






10. Install the front subframe (A) in its original position by aligning it with the marks (B) you made in the removal procedure.






11. Install three new bolts for the rear transmission mount.






12. Loosely install a new front engine mount bracket bolt (A) a new nut (B).

13. 4WD: Install the propeller shaft. Propeller Shaft Installation (4WD)

14. Install the intermediate shaft. Intermediate Shaft Installation

15. Install the front driveshafts. Front Driveshaft Installation

16. Connect the ball joint to the lower arm, Front Lower Arm Replacement and the front stabilizer link to the lower arm. Front Stabilizer Link Removal/Installation

17. Lower the vehicle on the lift.






18. Install the transmission mount bolt (A) and the transmission mount bracket bolt (B) and nuts (C).

19. Raise the vehicle on the lift.






20. Tighten the front engine mount bracket mounting bolt.

21. Refill the transmission with the recommended transmission fluid. MTF Inspection and Replacement






22. Install the splash shield (A).

23. Lower the vehicle on the lift.






24. Install the two upper transmission mounting bolts.

25. Remove the engine support hanger and the engine hanger/adapter from the engine. Then install the purge joint pipe to the threaded hole in the cylinder head.






26. Apply super high temp urea grease (P/N 08798-9002) to the end of the cylinder rod. Install the slave cylinder (A) and the clutch line bracket (B). Be careful not to bend the clutch line (C).






27. Apply a light coat of silicone grease (P/N 08C30-B0234M) to the shift cable ends (A).
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.

28. Install the shift cable bracket (B) and the shift cables (C), then install the new cotter pins (D) or the lock pins (E).

'07-08 models





'09 model





29. Connect the output shaft (countershaft) speed sensor connector (A) and the back-up light switch connector (B).

30. Install the ground cable (C).

31. Place a floor jack under the lower arm, and raise the suspension to load it with the vehicle's weight.

32. Retighten the lower arm ball joint castle nut and the front stabilizer link mounting nut to the specified torque.

33. Install the battery base. Engine Installation

34. Install the intake air duct. Engine Installation

35. Install the air cleaner assembly. Service and Repair

36. Do the battery installation procedure. Removal and Replacement

37. Check the shift lever and the clutch operation.

38. Check the wheel alignment. Service and Repair

39. Test-drive the vehicle.