Transmission Replacement

Transmission Replacement

Removal Procedure
1. Remove the control lever knob and boot assembly.





2. Remove the clutch hose/pipe assembly retainer clip (1) from the clutch master cylinder.
3. Disconnect the clutch hose/pipe assembly (2) from the clutch master cylinder.
4. Cap the clutch hose/pipe assembly (2) in order to prevent fluid loss and contamination. It is not necessary to plug the lower hose end or slave cylinder fitting as they are equipped with check valves, only minimal fluid loss may be experienced.
5. Drain the transmission fluid if necessary. Refer to Transmission Fluid Replacement.
6. Remove the rear propeller shaft.





7. Disconnect the following engine wiring harness electrical connectors:
^ Backup lamp switch (1)
^ Oxygen sensor (2)
8. Disconnect the engine wiring harness clip (3) from the clip bracket, and position the harness over the transmission.





9. Disconnect the vehicle speed sensor (VSS) electrical connector (2)
10. Disconnect the engine wiring harness clips (1) from the clip brackets, and position the harness aside.
11. Remove the transmission support.





12. Remove the 5 transmission to engine mounting bolts (1).
13. Remove the 2 engine to transmission mounting bolts (2).





14. Remove the 2 remaining transmission mounting bolts (2).

15. Important: Do not allow the transmission to hang from the clutch assembly.

Pull the transmission straight back off the clutch hub splines.

16. Important: Ensure clearance is maintained between the transmission and the following:
^ The catalytic converter
^ The clutch assembly
^ The engine wiring harness

Using the transmission jack, carefully lower the transmission from the vehicle.

Installation Procedure

1. Important: Ensure clearance is maintained between the transmission and the following:
^ The catalytic converter
^ The clutch assembly
^ The engine wiring harness

Using the transmission jack, carefully raise the transmission to the engine.





2. Important: Do not allow the transmission to hang from the clutch assembly.

Align the transmission with the engine dowels (1).

3. Notice: Refer to Fastener Notice in Service Precautions.

Install the 2 transmission mounting bolts (2).

Tighten the bolts to 50 Nm (37 ft. lbs.).





4. Install the 2 engine to transmission mounting bolts (2).

Tighten the bolts to 50 Nm (37 ft. lbs.).

5. Install the 5 transmission to engine mounting bolts (1).

Tighten the bolts to 50 Nm (37 ft. lbs.).

6. Install the transmission support.
7. Remove the transmission jack from under the vehicle.





8. Connect the VSS electrical connector (2)
9. Connect the engine wiring harness clips (1) to the clip brackets.
10. Lay the engine wiring harness over the transmission.





11. Connect the following engine wiring harness electrical connectors:
^ Backup lamp switch (1)
^ Oxygen sensor (2)
12. Connect the engine wiring harness clip (3) to the clip bracket.
13. Install the rear propeller shaft.
14. Fill the transmission fluid if removed. Refer to Transmission Fluid Replacement.





15. Important: Ensure the clutch hydraulic hose does not come in contact with any sharp or potentially hot surfaces.

Install the clutch hose/pipe assembly retainer clip (2) to the clutch master cylinder.
16. Connect the clutch hose/pipe assembly (3) to the clutch master cylinder.
17. Tug gently on the clutch hose/pipe assembly (3) to ensure proper retention into the clutch master cylinder.
18. Install the control lever knob and boot assembly.

Transmission Final Test and Inspection
Complete the following procedure after the transmission is installed in the vehicle:
1. With the ignition OFF or disconnected and clutch pedal depressed, crank the engine several times. Listen for any unusual noises or evidence that any parts are binding.
2. Place the transmission in neutral, start the engine and listen for any unusual noises or evidence that any parts are binding.
3. Turn OFF the ignition.
4. Perform a final inspection for the proper fluid level. Refer to Transmission Fluid Replacement.
5. Road test the vehicle.