Manual Transmission Assembly

Removal & Installation

To Remove:

1. Open the front hood fully, and support with stay
2. Disconnect or remove the following
   • Ground cable from battery
   • Air intake duct and cleaner case or the air intake chamber
   • Air cleaner case stay
   • Intercooler (turbo model)
   • Neutral position switch connector
   • Back-up light switch connector
   • Vehicle speed sensor
   • Starter

   • Engine upper dog bone and set the st. St 41099aa000 engine support assy

   • Clutch operating cylinder from transmission

   • Clutch release fork from release bearing. (turbo model)
   • Plug using 10 mm hexagon wrench

   • Screw the 6 mm dia. bolt into release fork shaft, and then remove it
3. Raise the release fork and unfasten the release bearing tabs to free release fork

   CAUTION
   Step 3 is required to prevent interference with engine when removing the engine from transmission.

4. Remove or disconnect the following
   • Front and center exhaust pipes
   • Center exhaust pipe (turbo model)
   • Rear exhaust pipe and muffler

     CAUTION
     When removing the exhaust pipes, be careful each exhaust pipe does not drop out.

   • 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.

5. Pull out the front drive shaft from transmission (TURBO model)
   • Face the "MT" mark on ST toward transmission side (ST 28399SA000 DRIVE SHAFT REMOVER)
   • Insert the ST between transmission and front drive shaft (ST 28399SA000 DRIVE SHAFT REMOVER)

     CAUTION
     Contact the protrusion part of ST to transmission case.

   • While holding the joint portion (AAR) of front drive shaft with your hand, push the housing outside to remove from transmission
6. Place the transmission jack under transmission
7. Remove the following
   • Bell housing nuts and bolts

     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     Move the transmission jack toward rear until mainshaft is withdrawn from clutch cover.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
   • Clutch release bearing from engine side (Turbo model)

To Install:

1. Replace the differential side oil seal with a new one

   CAUTION
   It is not necessary to replace the oil seal if a new one is already installed.

2. Install or connect the following
   • Rear cushion rubber to transmission assembly
   • Torque Specification: 35 Nm (25.8 Ft. Lbs.)

   • Clutch release lever and bearing onto transmission (Turbo model)
   • Transmission onto engine
   • Transmission at splines by gradually raising it with transmission jack

     CAUTION
     Be careful not to strike the main shaft against clutch cover.

   • Transmission rear crossmember
   • Torque Specification: T1: 70 Nm (51 Ft. Lbs.) T2: 140 Nm (103 Ft. Lbs.)
3. Tighten the bell housing bolts and nuts
   • Torque Specification: 50 Nm (36.9 Ft. Lbs.)
4. Take off the transmission jack
5. Install the starter

6. Remove the ST
7. Install the dog bone
   • Torque Specification: T1: 50 Nm (37 Ft. Lbs.) T2: 58 Nm (43 Ft. Lbs.)

8. Install the front drive shaft into transmission
9. Drive the spring pin into chamfered hole of drive shaft

   CAUTION
   Always use a new spring pin.

10. Replace the cir-clip with a new one, and insert the front drive shaft to transmission (TURBO model) ST 28399SA010 FRONT DRIVE SHAFT OIL SEAL PROTECTOR
11. Install or connect the following
    • Ball joints of lower arm into knuckle arm of housing, and tighten the bolts
    • Torque Specification: 49 Nm (36 Ft. Lbs.)

    • Stabilizer link from transverse link
    • Torque Specification: 30 Nm (22.1 Ft. Lbs.)

    • Gear shift rod and stay
    • Gear shift rod onto transmission
    • Stay onto transmission
    • 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
    • Bearing into clutch cover by pushing the clutch release lever (turbo model)

    • Operating cylinder
    • Torque Specification: 37 Nm (27.5 Ft. Lbs.)
    • Transmission ground cable
    • Torque Specification: 13 Nm (9.4 Ft. Lbs.)
    • Vehicle speed sensor connector
    • Neutral position switch connector
    • Back-up light switch connector
    • Air cleaner case stay
    • Torque Specification: 16 Nm (11.6 Ft. Lbs.)
    • Air cleaner case or the air intake chamber and duct
    • Intercooler (TURBO model)