MANUAL TRANSMISSION ASSEMBLY INSTALLATION

PROCEDURE


  1. INSTALL TRANSFER ASSEMBLY

    Click here

  2. INSTALL MANUAL TRANSMISSION UNIT ASSEMBLY


    1. B001FBU

      Confirm that 2 straight pins are on the manual transmission contact surface of the engine cylinder block before manual transmission installation.

    2. Align the input shaft with the clutch disc and install the transmission unit to the engine.

    3. B001G2WE02

      Install the 8 bolts.

      Torque:
      for bolt A
      72 N*m  { 729 kgf*cm, 52 ft.*lbf }
      for bolt B
      37 N*m  { 379 kgf*cm, 27 ft.*lbf }

  3. CONNECT TRANSFER AND MANUAL TRANSMISSION BREATHER HOSE SUB-ASSEMBLY


    1. Connect the 2 breather hoses to the bracket.

    2. Connect the 3 breather hoses to the transfer adapter and transfer.

  4. CONNECT WIRE HARNESS


    1. Connect the 2 connectors and 4 clamps.

  5. INSTALL MANIFOLD STAY

    Click here

  6. INSTALL REAR NO. 1 ENGINE MOUNTING INSULATOR


    1. B001HL5E03

      Install the mounting insulator and front engine mounting insulator with the 5 bolts.

      Torque:
      for bolt A
      73 N*m  { 739 kgf*cm, 54 ft.*lbf }
      for bolt B
      12 N*m  { 117 kgf*cm, 8 ft.*lbf }

  7. INSTALL NO. 3 FRAME CROSSMEMBER SUB-ASSEMBLY


    1. Install the frame crossmember with the 4 bolts and 4 nuts.

      Torque:
      72 N*m  { 734 kgf*cm, 53 ft.*lbf }

    2. Install the 4 bolts to the mounting insulator.

      Torque:
      30 N*m  { 306 kgf*cm, 22 ft.*lbf }

  8. INSTALL FRONT SUSPENSION MEMBER BRACKET LH


    1. Install the member bracket with the 4 bolts.

      Torque:
      33 N*m  { 337 kgf*cm, 24 ft.*lbf }

  9. INSTALL FRONT SUSPENSION MEMBER BRACKET RH


    1. Install the member bracket with the 4 bolts.

      Torque:
      33 N*m  { 337 kgf*cm, 24 ft.*lbf }

  10. INSTALL STARTER ASSEMBLY


    1. for 1.4 kW Type:

      Install the starter Click here.

    2. for 2.0 kW Type:

      Install the starter Click here.

  11. CONNECT CLUTCH RELEASE CYLINDER ASSEMBLY


    1. Connect the clutch release cylinder with the 2 bolts.

      Torque:
      12 N*m  { 120 kgf*cm, 9 ft.*lbf }

  12. INSTALL FRONT PROPELLER SHAFT ASSEMBLY


    1. Install the front propeller shaft Click here.

  13. INSTALL PROPELLER SHAFT ASSEMBLY


    1. Install the propeller shaft Click here.

  14. ADD MANUAL TRANSMISSION OIL

  15. INSTALL TRANSFER CASE LOWER PROTECTOR


    1. Install the lower protector with the 4 bolts.

      Torque:
      18 N*m  { 184 kgf*cm, 13 ft.*lbf }

  16. INSTALL SHIFT LEVER ASSEMBLY


    1. B001HW4

      Apply MP grease to the tip of the shift lever assembly.

      Text in Illustration
      B001CHY MP Grease

    2. Cover the shift lever cap with a cloth.

    3. B001CQRE02
      Text in Illustration
      *1 Shift Lever Cap
      *a Press down
      *b Clockwise
      *c Lock

      While pressing down on the shift lever cap, turn it clockwise to install the shift lever assembly.

  17. INSTALL NO. 1 SHIFT AND SELECT LEVER BOOT


    1. Install the shift and select lever boot with the 4 screws.

    2. Attach the 2 clips.

  18. INSTALL CONSOLE PANEL SUB-ASSEMBLY

    for Manual Transmission: Click here

    w/ Refrigerated Cool Box: Click here

  19. INSTALL SHIFT LEVER KNOB SUB-ASSEMBLY


    1. Install the knob to the shift lever.

  20. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

    Note

    When disconnecting the cable, some systems need to be initialized after the cable is reconnected Click here.