MANUAL TRANSMISSION ASSEMBLY INSTALLATION

INSTALL TRANSMISSION CONTROL CABLE BRACKET NO.1
1. Install the transmission control cable bracket No.1 with the 2 bolts.
  
  Torque:
  
  28 N*m { 286 kgf*cm, 21 ft.*lbf }
INSTALL REAR ENGINE MOUNTING INSULATOR ASSEMBLY
1. Install the engine mounting insulator assembly rear with the 4 bolts.
  
  Torque:
  
  29 N*m { 296 kgf*cm, 21 ft.*lbf }
INSTALL MANUAL TRANSMISSION UNIT ASSEMBLY
1. Install the transmission unit assembly with the 8 bolts.
  
  Torque:
  
  Bolt A
  
  72 N*m { 729 kgf*cm, 53 ft.*lbf }
  
  Bolt B
  
  69 N*m { 700 kgf*cm, 51 ft.*lbf }
  
  Bolt C
  
  37 N*m { 377 kgf*cm, 27 ft.*lbf }
2. Install the transmission unit assembly with the bolt, nut and 2 washers to the frame.
  
  Torque:
  
  98 N*m { 999 kgf*cm, 72 ft.*lbf }
  Note
  
  Insert the bolt from the left side of the vehicle.
  
  Tighten the nut while holding the bolt.
INSTALL STARTER ASSEMBLY (for 2.2 kW Type)
1. Install the starter with the 2 bolts and nut.
  
  Torque:
  
  69 N*m { 700 kgf*cm, 51 ft.*lbf }
2. Install the stay with the 2 bolts and nut.
  
  Torque:
  
  69 N*m { 104 kgf*cm, 51 ft.*lbf }
3. Connect the 30 terminal with the nut.
  
  Torque:
  
  9.8 N*m { 100 kgf*cm, 7 ft.*lbf }
4. Install the terminal cap.
5. Connect the starter connector.
INSTALL STARTER ASSEMBLY (for 2.7 kW Type)
1. Install the starter with the 2 bolts, nut and stay.
  
  Torque:
  
  69 N*m { 700 kgf*cm, 51 ft.*lbf }
2. Install the starter stay with the 2 bolts and nut.
  
  Torque:
  
  Bolt
  
  37 N*m { 380 kgf*cm, 27 ft.*lbf }
  
  Nut
  
  12.5 N*m { 130 kgf*cm, 9 ft.*lbf }
3. Connect the 30 terminal with the nut.
  
  Torque:
  
  21 N*m { 215 kgf*cm, 16 ft.*lbf }
4. Install the terminal cap.
5. Connect the starter connector.
INSTALL CLUTCH RELEASE CYLINDER ASSEMBLY
1. Install the clutch release cylinder with the 2 bolts.
  
  Torque:
  
  12 N*m { 120 kgf*cm, 9 ft.*lbf }
CONNECT WIRE HARNESS
1. Connect the 2 connectors and clamp.
INSTALL TRANSMISSION CONTROL CABLE ASSEMBLY
1. Install 2 new clips to the transmission control cable bracket No.1.
2. Install the transmission control cable assembly to the transmission control cable bracket No.1.
  Note
  - Be sure that A claws of the clips are firmly engaged into the bracket grooves.
  - Be sure the cable is set in the clip with both B claws erected to prevent slippage of the cable in the opposite direction.
3. Align the matchmarks on the control cable assembly and the outer lever.
4. Install the transmission control cable assembly to the outer levers with the 2 nuts.
  
  Torque:
  
  37 N*m { 377 kgf*cm, 27 ft.*lbf }
INSTALL PROPELLER SHAFT ASSEMBLY (for Long Wheelbase)
1. Remove the SST from the extension housing.
2. Install the propeller shaft assembly in the extension housing.
3. Align the matchmarks on the propeller shaft flange and differential flange.
4. Install the propeller shaft assembly with the 4 nuts, 4 bolts and 4 washers.
  
  Torque:
  
  74 N*m { 755 kgf*cm, 54 ft.*lbf }
INSTALL PROPELLER WITH CENTER BEARING SHAFT ASSEMBLY (for Super Long Wheelbase)
1. Remove the SST from the extension housing.
2. Install the propeller with center bearing shaft assembly in the extension housing.
3. Install the center support bearing assembly No.1, and temporarily tighten the 2 bolts.
4. Align the matchmarks on the propeller shaft flange and differential flange.
5. Install the propeller shaft assembly with the 4 nuts, 4 bolts and 4 washers.
  
  Torque:
  
  74 N*m { 755 kgf*cm, 54 ft.*lbf }
6. Check that the center line of the bracket is at right angles to the shaft axial direction.
7. Adjust the center support bearing assembly No.1.
  Tech Tips
  
  With the vehicle unladen, adjust the center support bearing No.1 to maintain the angles, as shown.
  
  In the same conditions, check the center line in the axial direction. Adjust the bearing if necessary.
  
  The center bearing center line and center bearing housing center line must be adjusted to within -1.0 to 1.0 mm (-0.0394 to 0.0394 in.) of each other in the vehicle's longitudinal direction with the vehicle unladen.
8. Tighten the 2 bolts.
  
  Torque:
  
  36 N*m { 369 kgf*cm, 27 ft.*lbf }
INSTALL EXHAUST PIPE ASSEMBLY FRONT NO.2 (for Long Wheelbase)
1. Inspect the compression spring.
  1. Using vernier calipers, measure the free length of the compression springs.
    
    Minimum length
    
    40.5 mm (1.594 in.)
    
    Tech Tips
    
    If the free length is less than the minimum, replace the compression spring.
2. Install the gasket.
  1. Fully insert a new gasket to the exhaust pipe sub-assembly front No.1 by hand.
  2. Using a wooden block, uniformly strike the gasket so that the gasket and exhaust pipe sub-assembly front No.1 are properly fit.
    
    Note
    
    Be careful with the installation direction of the gasket.
    
    Do not damage the outer face.
    
    Do not reuse the gasket.
    
    To ensure a proper seal, do not use the exhaust pipe sub-assembly front No.2 to force the gasket onto the exhaust pipe sub-assembly front No.1.
3. Connect the exhaust pipe support, and install a new gasket and the exhaust pipe sub-assembly front No.2 with the 4 bolts, 2 nuts, and 2 compression springs.
  
  Torque:
  
  Exhaust pipe sub-assembly front No.1 side
  
  43 N*m { 438 kgf*cm, 32 ft.*lbf }
  
  Exhaust pipe assembly tail side
  
  48 N*m { 489 kgf*cm, 35 ft.*lbf }
  
  Note
  
  After installation, check that the clearance is almost same at any point between the flanges of the exhaust pipe sub-assembly front No.2 and exhaust pipe sub-assembly front No.1.
INSTALL EXHAUST PIPE ASSEMBLY FRONT NO.2 (for Super Long Wheelbase)
1. Inspect the compression spring.
  1. Using vernier calipers, measure the free length of the compression springs.
    
    Minimum length
    
    40.5 mm (1.594 in.)
    
    Tech Tips
    
    If the free length is less than the minimum, replace the compression spring.
2. Install the gasket.
  1. Fully insert a new gasket to the exhaust pipe sub-assembly front No.1 by hand.
  2. Using a wooden block, uniformly strike the gasket so that the gasket and exhaust pipe sub-assembly front No.1 are properly fit.
    
    Note
    
    Be careful with the installation direction of the gasket.
    
    Do not damage the gasket.
    
    Do not reuse the gasket.
    
    To ensure a proper seal, do not use the exhaust pipe sub-assembly front No.2 to force the gasket onto the exhaust pipe sub-assembly front No.1.
3. Connect the exhaust pipe support, and install a new gasket and the exhaust pipe sub-assembly front No.2 with the 4 bolts, 2 nuts, and 2 compression springs.
  
  Torque:
  
  Exhaust pipe sub-assembly front No.1 side
  
  43 N*m { 438 kgf*cm, 32 ft.*lbf }
  
  Exhaust pipe assembly center side
  
  48 N*m { 489 kgf*cm, 35 ft.*lbf }
  
  Note
  
  After installation, check that the clearance is almost same at any point between the flanges of the exhaust pipe sub-assembly front No.2 and exhaust pipe sub-assembly front No.1 .

Minimum length
40.5 mm (1.594 in.)

Minimum length
40.5 mm (1.594 in.)

ADD MANUAL TRANSMISSION OIL

Park the vehicle in a level place.
Remove the transmission filler plug and gasket.

Check that the oil surface is within 5 mm (0.20 in.) below the lowest point of the transmission filler plug opening.

Oil grade
API GL-4
Viscosity
SAE 75W-90
Capacity
2.2 liters (2.3 US qts, 1.9 Imp. qts)

Note

Problems may occur when the oil level is too high or too low.
After replacing the oil, drive the vehicle and check the oil level again.

Check for oil leakage if the oil level is low.
Install the transmission filler plug and a new gasket.

Torque:

37 N*m { 377 kgf*cm, 27 ft.*lbf }

CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
CHECK FOR EXHAUST GAS LEAKS
PERFORM INITIALIZATION

Some systems need initialization after reconnecting the cable to the negative battery terminal Click here.