M/T Assembly Installation

1.Check that the two dowel pins are installed in the clutch housing.

2.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.

 

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

4.Push the transmission towards engine until mainshaft engages with the spline of pressure plate.

5.Install the lower transmission mounting bolts.

 

 

6.Install the intercooler pipe.

 

7.Install the transmission mount (A).

 

8.Install the stud bolts (B).

9.Hand-tighten the transmission mount bolt (A), use a new bolt.

 

10.Install the bolt, nuts, and ground cable bolt, use a new bolts, and nuts.

11.Tighten the transmission mount bolt (A).

12.Change the new subframe plate (A).

 

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

 

14.Install the front suspension subframe. Line up the mark each subframe and body.

 

15.Tighten the bolts, use the new bolts.

16.Install the transmission lower mount.

 

17.Install the intermediate shaft.

18.For 4WD models, install the propeller shaft.

19.Install the lower torque rod.

 

20.Install the inboard joint of driveshafts.

21.Install the knuckle onto the lower arm.

22.Connect the front stabilizer.

23.Install the splash shield.

 

24.Remove the chain hoist and engine hanger.

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

 

26.Connect the back-up light switch connector (A), countershaft speed sensor connector (B) and reverse lockout solenoid connector (C).

 

27.Install the cable bracket (A) and cables (B).

 

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

29.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.

 

30.Do the engine mount positioning.

31.Install the battery base bracket.

 

32.Install the resonator chamber.

 

33.Install the battery base.

 

34.Install the air cleaner housing.

35.Install the battery. Connect the positive (+) cable first, then the negative (-) cable to the battery.

36.Refill the transmission fluid.

37.Check the clutch operation.

38.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.)

39.Check the front wheel alignment.

40.Enter the anti-theft codes for the radio and navigation system, then enter the customer's radio station presets.

41.Do the power window control unit reset procedure.

42.Test-drive the vehicle.