Manual transmission ASSY
Components Removal / installation
MANUAL TRANSMISSION / TRANSAXLE
MANUAL TRANSMISSION ASSY
EXPLODED VIEW
REMOVAL
1. Disconnection of battery ground terminal (refer to 
)
)2. Removal of under cover front AL (refer to )
)3. Removal of under cover COMPL T/M (refer to )
)
4. Removal of engine under cover RR RH (with rear spoiler)
(1) Remove 3 bolts and 8 clips to remove the engine under cover RR RH.
5. Removal of engine under cover RR LH (with rear spoiler)
NOTE:
Perform the same procedures for the LH side.
6. Drain of manual transmission oil (refer to )
)7. Removal of exhaust manifold
(Refer to )
)8. Removal of propeller shaft with center bearing ASSY
(Refer to )
)9. Removal of stabilizer bar FR
(Refer to )
)10. Removal of starter ASSY
(Refer to )
)11. Disconnection of wiring harness
NOTE:
Secure the disconnected harnesses using tape, etc. to keep them out of the way.
(1) Release the lock of the connector A to move the lock lever, and disconnect the connector.
Captions in illustration
 |
Lock unit |
(2) Disconnect the connector B.
(3) Disconnect the 2 connectors.
(4) Remove the bolts, then disconnect the ground cable.
(5) Release the clamp and disconnect the wiring harness.
(6) Remove the bolt and disconnect the wiring harness clamp bracket.
12. Disconnection of clutch release cylinder ASSY
(1) Remove 2 bolts to disconnect the clutch release cylinder ASSY.
NOTE:
Hang the clutch release cylinder ASSY with rope, etc. not to apply excessive force to the clutch pipe.
13. Install the SST to the engine unit.
Standard value:
Standard value:
Tightening torque=43N·m
{
438kgf·cm}
{31.7 ft-lb}
SST
12281-38150
Engine hanger No.1)
901191420
Bolt)
14. Remove the clip securing the bulkhead harness to the vehicle.
·Left hand
·Right hand
·Right hand15. Set the SST to the vehicle to support the engine.
SST
99099AJ000
Engine hanger)
18679AA020
Adjuster)
CAUTION:
·Keep the harness from being caught in when setting the SST on the vehicle.
·Use a shackle with the load capacity of 250 kg (551 lb) or more.
·Use a shackle with the load capacity of 250 kg (551 lb) or more.
16. Turn the handle on the top of the SST clockwise to lift the engine gradually until the stud bolt of the engine mounting is pulled out from the engine mounting hole of the crossmember.
CAUTION:
·To prevent damage to the SST threaded portion, turn the handle after applying grease or lubricants to the SST threaded portion.
·To prevent damage caused by contact of parts, lift gradually while paying attention to the clearance of each part.
·To prevent damage caused by contact of parts, lift gradually while paying attention to the clearance of each part.
17. Disconnection of manual transmission ASSY
(1) Remove the bolt connecting the manual transmission ASSY.
18. Disconnection of floor shift control shaft
(1) Turn up the shift & select lever boot and remove the clip and the plate washer.
(2) Disconnect the floor shift control shaft from the lever CP.
(3) Remove the shift & select lever boot.
19. Removal of exhaust pipe support No.1
(1) Remove 2 bolts to remove the exhaust pipe support No.1.
20. Support of manual transmission ASSY
(1) Hold the manual transmission ASSY.
CAUTION:
·Make sure that the manual transmission ASSY is placed at the center of the cradle of the high mission jack.
·Securely hold the engine ASSY to prevent it from tilting when removing the manual transmission ASSY.
·Securely hold the engine ASSY to prevent it from tilting when removing the manual transmission ASSY.
21. Removal of engine rear mounting member
(1) Remove 4 bolts, 2 nuts, and 2 washers to remove the engine rear mounting member.
22. Removal of shift lever pin
(1) Release the lock and pull out the 2 shift lever pins.
23. Removal of manual transmission ASSY
(1) Remove 3 bolts and 2 nuts to remove the manual transmission ASSY.
Captions in illustration
 |
Bolt |
|
|
Nut |
CAUTION:
·Retract the high mission jack until the input shaft is pulled out from the clutch cover.
·Be careful not to damage the extension housing breather plug.
·Do not shake the manual transmission ASSY excessively to prevent damage to the input shaft.
·To prevent damage to the knock pin, do not pry apart the contact surface of the manual transmission ASSY and the engine ASSY excessively.
·Be careful not to damage the extension housing breather plug.
·Do not shake the manual transmission ASSY excessively to prevent damage to the input shaft.
·To prevent damage to the knock pin, do not pry apart the contact surface of the manual transmission ASSY and the engine ASSY excessively.
NOTE:
If it is difficult to remove the manual transmission ASSY, use a KTC mighty bar or equivalent to pry apart the joint between the manual transmission ASSY and engine ASSY and remove the manual transmission ASSY.
Captions in illustration
|
|
Point to apply KTC mighty bar or equivalent |
(2) Remove 4 bolts to remove the engine mounting insulator RR No.1.
(3) Remove the lever CP. (Refer to )
)
(4) Remove the control shift lever retainer SUB-ASSY from the control shift lever retainer.
(5) Remove the 2 outer bushings and 2 inner bushings from the control shift lever retainer.
24. Removal of floor shift control shaft
(1) Remove the clip and the plate washer, and remove the floor shift control shaft.
(2) Remove the 2 collars from the knuckle.
25. Removal of knuckle
(1) Release the crimp on the control shaft collar.
(2) After sliding the control shaft collar, press down the pin with the L-shaped tool and push it up, then pull it out with pliers while applying a cloth to prevent damage to the pin.
(3) Remove the knuckle and the control shaft collar from the manual transmission ASSY.
Captions in illustration
| *1 |
Control shaft collar |
| *2 |
Pin |
(4) Remove the cushion from the knuckle.
INSTALLATION
1. Installation of knuckle
(1) Install a new control shaft collar to the shift shaft.
Captions in illustration
| *1 |
Control shaft collar |
| *2 |
Pin |
(2) Install the cushion to the knuckle.
(3) Install the knuckle to the shift shaft.
(4) Drive in the pin.
(5) Slide the control shaft collar until it reaches to the knuckle stopper, and crimp the control shaft collar.
2. Installation of floor shift control shaft
3. Installation of control shift lever retainer
(1) Install 2 inner bushings and 2 outer bushings to the control shift lever retainer.
(2) Apply NIGTIGHT LYW No.2 or equivalent to the tip of the control shift lever retainer.
Captions in illustration
|
|
NIGTIGHT LYW No.2 or equivalent |
(3) Install the control shift lever retainer SUB-ASSY to the control shift lever retainer.
(4) Install the lever CP. (Refer to )
)4. Installation of manual transmission ASSY
(1) Make sure that the knock pins are attached to 2 locations on the engine side.
(2) Keep the engine and the manual transmission ASSY horizontal, then align the knock pins and the knock pin holes and tighten the 3 bolts and 2 nuts shown in the figure.
Standard value:
Standard value:
Tightening torque=50N·m
{
510kgf·cm}
{36.9ft·lbf}
Captions in illustration
|
|
Bolt |
|
|
Nut |
CAUTION:
·Do not shake the transmission ASSY excessively to prevent damage to the input shaft.
·Before installing the transmission ASSY, check that there are 2 knock pins on the engine transmission installing surface.
·Do not shake the transmission ASSY excessively to prevent damage to the knock pins.
·Be careful not to damage the extension housing breather plug.
·Be sure to install the transmission ASSY with the input shaft engaged to the clutch disc spline. Otherwise the clutch disc may be damaged and cause noise.
·Before installing the transmission ASSY, check that there are 2 knock pins on the engine transmission installing surface.
·Do not shake the transmission ASSY excessively to prevent damage to the knock pins.
·Be careful not to damage the extension housing breather plug.
·Be sure to install the transmission ASSY with the input shaft engaged to the clutch disc spline. Otherwise the clutch disc may be damaged and cause noise.
(3) Apply NIGTIGHT LYW No.2 or equivalent to the tip of new shift lever pins.
Captions in illustration
|
|
NIGTIGHT LYW No.2 or equivalent |
(4) Install the control shift lever retainer to the manual transmission ASSY with 2 shift lever pins.
(5) Lock the 2 shift lever pins.
(6) Install the engine mounting insulator RR No.1 with 4 bolts.
Standard value:
Standard value:
Tightening torque=40N·m
{
408kgf·cm}
{29.5ft·lbf}
5. Installation of engine rear mounting member
(1) Install the engine rear mounting member with 4 bolts, 2 nuts, and 2 washers.
Standard value:
Standard value:
Tightening torque=55N·m
{
561kgf·cm}
{40.6ft·lbf} (nut)
Tightening torque=65N·m { 663kgf·cm} {47.9ft·lbf} (bolt)
Tightening torque=65N·m { 663kgf·cm} {47.9ft·lbf} (bolt)
6. Installation of exhaust pipe support No.1
(1) Install the exhaust pipe support No.1 with 2 bolts.
Standard value:
Standard value:
Tightening torque=23N·m
{
235kgf·cm}
{17.0ft·lbf}
7. Installation of floor shift control shaft
(1) Install the lever CP. (Refer to )
)(2) Apply Permalub ECN-9 or equivalent to the tip of the floor shift control shaft.
Captions in illustration
|
|
Permalub ECN-9 or equivalent |
(3) Install 2 collars and an O-ring to the lever CP.
(4) Connect the tip of the floor shift control shaft to the lever CP and install the plate washer and the clip, then install the shift & select boot.
8. Installation of manual transmission ASSY
(1) Tighten the connecting bolt on the manual transmission ASSY.
Standard value:
Standard value:
Tightening torque=50N·m
{
510kgf·cm}
{36.9ft·lbf}
9. Connection of clutch release cylinder ASSY
(1) Connect the clutch release cylinder ASSY with the 2 bolts.
Standard value:
Standard value:
Tightening torque=37N·m
{
377kgf·cm}
{27.3ft·lbf}
·RHD model
·LHD model
·LHD model
CAUTION:
When restoring the clutch release cylinder ASSY, check that the clutch hose is deflected in the same direction as shown in the figure.
10. Connection of wiring harness
(1) Install the wiring harness clamp bracket with the bolt.
Standard value:
Standard value:
Tightening torque=7.5N·m
{
77kgf·cm}
{5.5ft·lbf}
(2) Engage the clamp to connect the wiring harness.
(3) Connect the ground cable with the bolt.
Standard value:
Standard value:
Tightening torque=13N·m
{
133kgf·cm}
{9.6ft·lbf}
(4) Connect the 2 connectors.
(5) Connect the 2 connectors.
NOTE:
For connector A, push down the lever until a sound indicating the claw is hooked is heard.
11. Installation of starter ASSY
(Refer to )
)12. Installation of stabilizer bar FR
(Refer to )
)13. Installation of propeller shaft with center bearing ASSY
(Refer to )
)14. Installation of exhaust manifold
(Refer to )
)15. Fill of manual transmission oil (refer to )
)16. Check of manual transmission oil (refer to )
)17. Check of manual transmission oil leakage
18. Installation of engine under cover RR LH (with rear spoiler)
NOTE:
Perform the same procedures for the LH side.
19. Installation of engine under cover RR RH (with rear spoiler)
(1) Install the engine under cover RR RH with 3 bolts and 8 clips.
Standard value:
Standard value:
Tightening torque=7.5N·m
{
77kgf·cm}
{5.5ft·lbf}
20. Installation of under cover COMPL T/M (refer to )
)21. Installation of under cover front AL (refer to )
)