MANUAL TRANSMISSION ASSEMBLY INSTALLATION

INSTALL TRANSFER ASSEMBLY

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INSTALL MANUAL TRANSMISSION UNIT ASSEMBLY
1. Align the input shaft with the clutch disc and install the transmission to the engine.
2. Install the 4 bolts.
  
  Torque:
  
  72 N*m { 730 kgf*cm, 53 ft.*lbf }
INSTALL STIFFENER PLATE
1. Install the stiffener plate RH with the 4 bolts.
  
  Torque:
  
  69 N*m { 704 kgf*cm, 51 ft.*lbf, for bolt A }
  
  37 N*m { 377 kgf*cm, 27 ft.*lbf, for bolt B }
2. Install the stiffener plate LH with the 4 bolts.
  
  Torque:
  
  69 N*m { 704 kgf*cm, 51 ft.*lbf, for bolt A }
  
  37 N*m { 377 kgf*cm, 27 ft.*lbf, for bolt B }
INSTALL REAR NO. 1 ENGINE MOUNTING INSULATOR
1. Install the mounting insulator with the 4 bolts.
  
  Torque:
  
  44 N*m { 449 kgf*cm, 32 ft.*lbf }
INSTALL NO. 3 FRAME CROSSMEMBER SUB-ASSEMBLY
1. Install the frame crossmember with the 4 bolts and 4 nuts.
  
  Torque:
  
  50 N*m { 510 kgf*cm, 37 ft.*lbf }
2. Install the 4 set bolts to the rear No. 1 engine mounting insulator.
  
  Torque:
  
  17 N*m { 173 kgf*cm, 13 ft.*lbf }
INSTALL STARTER ASSEMBLY

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CONNECT CLUTCH RELEASE CYLINDER ASSEMBLY
1. Install the release cylinder with the 2 bolts.
  
  Torque:
  
  12 N*m { 122 kgf*cm, 9 ft.*lbf }
CONNECT WIRE HARNESS
1. Transmission side:
  
  Connect the back-up light switch connector.
2. Transfer side:
  
  Connect the No. 1, No. 2 and No. 3 transfer indicator switch connectors, and vehicle speed sensor connector.
INSTALL FRONT EXHAUST PIPE ASSEMBLY

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INSTALL REAR PROPELLER SHAFT ASSEMBLY

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INSTALL FRONT PROPELLER SHAFT ASSEMBLY

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ADD MANUAL TRANSMISSION OIL
1. Stop the vehicle on a level surface.
2. Remove the filler plug and gasket.
3. Check that the oil level is between 0 to 5 mm (0 to 0.20 in.) from the bottom lip of the filler plug opening.
  
  If the result is not as specified, add transmission oil.
  
  Oil grade
  
  GL-4
  
  Viscosity
  
  SAE 75W-90, 80W or 80W-90
  
  Standard capacity
  
  2.6 liters (2.7 US qts, 2.3Imp. qts)
  Note
  - Too much or too little oil will lead to transmission problems.
  - After adjusting the oil level, drive the vehicle and check the oil level again.
4. Check for oil leakage when the oil level is low. If leakage is found, repair the area necessary to stop the leak. Replace damaged parts as necessary.
5. Install a new gasket and the filler plug.
  
  Torque:
  
  37 N*m { 377 kgf*cm, 27 ft.*lbf }
INSTALL NO. 2 ENGINE UNDER COVER

Torque:

28 N*m { 286 kgf*cm, 21 ft.*lbf }
INSTALL NO. 1 ENGINE UNDER COVER

Torque:

28 N*m { 286 kgf*cm, 21 ft.*lbf }
INSTALL TRANSFER CASE LOWER PROTECTOR
1. Install the transfer case lower protector with the 4 bolts.
  
  Torque:
  
  18 N*m { 183 kgf*cm, 13 ft.*lbf }
INSTALL TRANSFER HIGH AND LOW SHIFT LEVER ASSEMBLY
1. Install the transfer shift lever.
2. Using pliers, install the snap ring.
  
  Tech Tips
  
  Apply MP grease to the tip of the transfer shift lever.
INSTALL FLOOR SHIFT SHIFT LEVER ASSEMBLY
1. Cover the shift lever cap with a cloth.
2. Press down on the shift lever cap and rotate it clockwise to install it.
  
  Tech Tips
  
  Apply MP grease to the tip of the shift lever.
INSTALL SHIFT LEVER BOOT ASSEMBLY
1. Install the shift lever boot with the 4 screws and 2 clips.
2. w/o Console Box:
  
  Install the floor carpet, front seat, front door scuff plate, etc.
INSTALL CONSOLE BOX ASSEMBLY

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CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
PERFORM INITIALIZATION
1. Perform initialization Click here.
  
  Note
  
  Certain systems need to be initialized after disconnecting and reconnecting the cable from the negative (-) battery terminal.
CHECK SRS WARNING LIGHT

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