Transmission Replacement

MANUAL TRANSMISSION UNIT ASSY (R155F)








COMPONENTS

REPLACEMENT
1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL
2. REMOVE CONSOLE UPPER REAR PANEL SUB-ASSY (SEPARATE SEAT TYPE)
3. REMOVE CONSOLE BOX ASSY REAR (SEPARATE SEAT TYPE)
4. REMOVE CONSOLE BOX FRONT (SEPARATE SEAT TYPE)
5. REMOVE CONSOLE BOX FRONT (BENCH SEAT TYPE)





6. REMOVE SHIFT LEVER BOOT ASSY
a. Remove the 2 screws A, 2 clips B and floor shift lever assy.





7. REMOVE FLOOR SHIFT SHIFT LEVER ASSY
a. Cover the shift lever cap with a cloth.
b. While pressing down on the shift lever cap, turn it counterclockwise to remove.
c. Pull out the shift lever.
8. REMOVE ENGINE UNDER COVER SUB-ASSY NO.2 (W/ ENGINE UNDER COVER NO.2)
a. Remove the 4 bolts and engine under cover No.2.
9. DRAIN MANUAL TRANSMISSION OIL
Torque: 37 Nm (377 kgf-cm, 27 ft. lbs.)
10. REMOVE EXHAUST PIPE ASSY FRONT
11. REMOVE PROPELLER SHAFT ASSY FRONT
12. REMOVE PROPELLER W/ CENTER BEARING SHAFT ASSY (ACCESS CAB)
13. REMOVE PROPELLER SHAFT ASSY (REGULAR CAB)
14. REMOVE STARTER ASSY





15. REMOVE MANIFOLD STAY
a. Remove the 3 bolts and manifold stay.





16. SEPARATE CLUTCH RELEASE CYLINDER ASSY
a. Remove the 2 bolts and separate the clutch release cylinder assy.





17. REMOVE FRAME CROSSMEMBER SUB-ASSY NO.3
a. Support the transfer with a support stand.





b. Remove the 4 bolts from the engine rear mounting.
c. Remove the 4 bolts, nuts and frame crossmember sub-assy No.3.





18. REMOVE ENGINE MOUNTING INSULATOR REAR NO.1
a. Remove the 4 bolts and engine mounting insulator rear No.1.
b. Using a transmission jack, support the transmission unit assy.
c. Remove the support stand from the rear side of the transfer.
19. DISCONNECT WIRE HARNESS
a. Tilt the transmission assy downward.

NOTICE: Make sure that the cooling fan does not come in contact with the fan shroud.

b. Disconnect the back-up lamp switch connector.
c. Disconnect the speed sensor connector.
d. Disconnect the 2 transfer indicator switch connectors.
e. Disconnect the transfer shift actuator motor connector.
f. Disconnect the wire harness clamp from the transmission w/ transfer assy.





20. REMOVE MANUAL TRANSMISSION W/ TRANSFER
a. Remove the 7 bolts and remove the transmission assy.
21. REMOVE TRANSFER ASSY
22. INSTALL TRANSFER ASSY





23. INSTALL MANUAL TRANSMISSION W/ TRANSFER
a. Align the input shaft with the clutch disc and install the transmission unit assy onto the engine.
b. Install the 7 bolts.
Torque:
72 Nm (730 kgf-cm, 53 ft. lbs.) for bolt A
37 Nm (379 kgf-cm, 27 ft. lbs.) for bolt B and C

HINT: Install bolt B from the front of the vehicle direction.

24. CONNECT WIRE HARNESS
a. Connect the wire harness clamp to the transmission w/ transfer assy.
b. Connect the back-up lamp switch connector.
c. Connect the speed sensor connector.
d. Connect the 2 transfer indicator switch connectors.
e. Connect the transfer shift actuator motor connector.





25. INSTALL ENGINE MOUNTING INSULATOR REAR NO.1
a. Install the engine mount insulator rear No.1 with 4 bolts onto the transmission assy.
Torque: 65 Nm (663 kgf-cm, 48 ft. lbs.)





26. INSTALL FRAME CROSSMEMBER SUB-ASSY NO.3
a. Install the frame crossmember sub-assy No.3 with the 8 bolts and nuts.
Torque: 40 Nm (408 kgf-cm, 30 ft. lbs.)
b. Install the 4 bolts onto the engine mounting insulator rear No.1.
Torque: 19 Nm (189 kgf-cm, 14 ft. lbs.)





27. INSTALL CLUTCH RELEASE CYLINDER ASSY
a. Install the clutch release cylinder assy with the 2 bolts.
Torque: 12 Nm (122 kgf-cm, 9 ft. lbs.)
28. INSTALL STARTER ASSY





29. INSTALL MANIFOLD STAY
a. Install the manifold stay with the 3 bolts.
Torque:
72 Nm (730 kgf-cm, 53 ft. lbs.) for bolt A
44 Nm (449 kgf-cm, 33 ft. lbs.) for bolt B
30 Nm (306 kgf-cm, 22 ft. lbs.) for bolt C
30. INSTALL PROPELLER W/ CENTER BEARING SHAFT ASSY (ACCESS CAB)
31. INSTALL PROPELLER SHAFT ASSY (REGULAR CAB)
32. INSTALL PROPELLER SHAFT ASSY FRONT
33. INSTALL EXHAUST PIPE ASSY FRONT
34. ADD MANUAL TRANSMISSION OIL
35. ADJUST MANUAL TRANSMISSION OIL
36. INSTALL ENGINE UNDER COVER NO. 2 (W/ ENGINE UNDER COVER NO.2)
a. Install the engine under cover No.2 with the 4 bolts.
Torque: 30 Nm (306 kgf-cm, 22 ft. lbs.)





37. INSTALL FLOOR SHIFT SHIFT LEVER ASSY
a. Cover the shift lever cap with a cloth.
b. While pressing down on the shift lever, turn it clockwise to install.

HINT: Apply MP grease to the tip of the shift lever.





38. INSTALL SHIFT LEVER BOOT ASSY
a. Install the shift lever boot assy with the 2 screws A and 2 clips B.
39. INSTALL CONSOLE BOX FRONT (BENCH SEAT TYPE)
40. INSTALL CONSOLE BOX FRONT (SEPARATE SEAT TYPE)
41. INSTALL CONSOLE BOX ASSY REAR (SEPARATE SEAT TYPE)
42. INSTALL CONSOLE UPPER REAR PANEL SUB-ASSY (SEPARATE SEAT TYPE)
43. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
Torque: 3.9 Nm (40 kgf-cm, 35 inch lbs.)
44. CHECK FOR MANUAL TRANSMISSION OIL LEAKAGE