M/T Assembly Installation

  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 transmission mount (A).
  1. Install the stud bolts (B).

  1. Install the transmission mount bolts and nuts.

  1. Support the subframe with a 4 x 4 x 40 in. piece of wood and a jack.

  1. Install the front suspension subframe (A) and front suspension subframe stays (B).

  1. Align the reference marks (A) with edge (B) of both rear stiffeners (C), and tighten the rear subframe mounting bolts, then front bolts, and tighten the stiffener bolts to the specified torque.

  1. Install the middle subframe mounting bolts.

  1. Install the transmission lower mount.

  1. Install the power steering line to the subframe (three clamps (A) and one mounting bracket bolt (B)).

  1. Install the power steering line bracket mounting bolt (A) and shift cable bracket mounting bolts (B).

  1. Install the lower torque rod.

  1. Install the exhaust pipe A and new gaskets (B).

  1. Install the splash shield.
  1. Remove the chain hoist and engine hanger.

  1. Install the harness (A), harness bracket (B), and transmission upper mounting bolts (C).

  1. Install the steering gearbox mounting bolts.
Right side:
Left side:

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

  1. Install the cable bracket (A) and cables (B).
  1. Apply a light coat of urea grease UM264 (P/N 41211-PY5-305) to the cable ends, and install new cotter pins (C).

  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. Install the resonator chamber.

  1. Install the ground cable (A), then install the battery base (B).
  1. Install the battery. Connect the positive (+) cable first, then the negative (−) cable to the battery.
  1. Test-drive the vehicle.
  1. Check the clutch operation.
  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 code for the radio and navigation system, then enter the customer's radio station presets.