Manual Transmission Assembly

Removal & Installation

To Remove:

1. Before servicing the vehicle, refer to the precautions at the beginning of this section.
2. Open the front hood fully, and support with stay.
3. Remove or disconnect the following:
   • Ground cable from battery
   • Air intake duct and cleaner case or the air intake chamber (non-turbo)
   • Air cleaner case stay (non-turbo)
   • Intercooler (turbo model)
4. Safely raise and support the vehicle.
5. Remove or disconnect the following:
   • The undercover
   • Neutral position switch connector
   • Back-up light switch connector
   • Vehicle speed sensor
   • Starter
   • Engine upper dog bone and set 41099aa000 engine support assembly or equivalent
   • Clutch operating cylinder from transmission
   • Clutch release fork from release bearing. (turbo model)
   • Plug (10 mm hexagon wrench)
6. Screw the 6 mm dia. bolt into release fork shaft, and remove.
7. Raise the release fork and unfasten the release bearing tabs to free release fork.
8. Remove or disconnect the following:
   • Bolt connecting the upper right side of transmission to engine
   • Front and center exhaust pipes
   • Center exhaust pipe (turbo model)
   • Rear exhaust pipe and muffler

     CAUTION
     When removing the exhaust pipes, be careful exhaust pipes do not drop.

   • Heat shield cover (If equipped)
   • Hanger bracket from right side of transmission
   • Propeller shaft
   • Gear shift rod and stay from transmission
   • Transmission stay
   • Transmission rod
   • Stabilizer link from transverse link
   • Bolt securing ball joint of transverse link to housing
   • Spring pins and separate the front drive shafts from each side of transmission (Non-Turbo model)

     CAUTION
     Discard the old spring pin and replace with a new one.

   • Front drive shaft from transmission (Turbo model)
   • Nuts holding the lower side of the transmission to the engine
9. Place the transmission jack under transmission.
10. Remove or disconnect the following:

    CAUTION
    Always support the transmission case with a transmission jack.

    • Transmission rear crossmember from vehicle
    • Transmission

      CAUTION
      Move the transmission jack toward rear until mainshaft is withdrawn from clutch cover.

    • Rear cushion rubber

To Install:

1. Install or connect the following:
   • Rear cushion rubber to transmission assembly
     1. Torque to: 26 ft. lbs. (35 Nm)
   • Clutch release lever and bearing onto transmission (Turbo model)
   • Transmission at splines by gradually raising it with transmission jack
   • Transmission rear crossmember
     1. T1 - Torque to: 51 ft. lbs. (70 Nm)
     2. T2 - Torque to: 103 ft. lbs. (140 Nm)
   • Nuts connecting the lower part of the transmission to the engine
     1. Torque to: 37 ft. lbs. (50 Nm)
2. Take off the transmission jack.
3. Install or connect the following:
   • Starter
   • Bolts connecting upper part of transmission to the engine
     1. Torque to: 37 ft. lbs. (50 Nm)
4. Remove the special tool.
5. Install or connect the following:
   • Bearing into clutch cover by pushing clutch release lever
   • Plug
     1. Torque to: 32.5 ft. lbs. (44 Nm)
   • Pitching stopper
     1. T1 - Torque to: 37 ft. lbs. (50 Nm)
     2. T2 - Torque to: 43 ft. lbs. (58 Nm)
6. Safely raise and support the vehicle.
7. Install or connect the following:
   • Front drive shaft into transmission
   • Spring pin into chamfered hole of drive shaft

     CAUTION
     Always use a new spring pin.

   • Ball joints of lower arm into knuckle arm of housing, and tighten the bolts
     1. Torque to: 36 ft. lbs. (49 Nm)
   • Stabilizer link from transverse link
     1. All except turbo sedan - Torque to: 22 ft. lbs. (30 Nm)
     2. Turbo sedan - Torque to: 33 ft. lbs. (45 Nm)
   • Gear shift rod and stay
   • Gear shift rod onto transmission
     1. Torque to: 13 ft. lbs. (18 Nm)
   • Stay onto transmission
     1. Torque to: 13 ft. lbs. (18 Nm)
   • Propeller shaft
   • Heat shield cover (if equipped)
   • Hanger bracket on right side of transmission
   • Rear exhaust pipe and muffler
   • Front exhaust pipe and center exhaust pipe
   • Center exhaust pipe (turbo model)
   • Under cover
   • Operating cylinder
     1. Torque to: 27.5 ft. lbs. (37 Nm)
   • Transmission ground cable
     1. Torque to: 114 inch lbs. (13 Nm)
   • Vehicle speed sensor connector
   • Neutral position switch connector
   • Back-up light switch connector
   • Air cleaner case stay
     1. Torque to: 11.6 ft. lbs. (16 Nm)
   • Air cleaner case or the air intake chamber and duct
   • Intercooler (Turbo model)
   • Battery ground terminal