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Transmission Replacement

MANUAL TRANSMISSION UNIT ASSY (R155)








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 LEVER ASSY
a. Cover the shift lever cap with a cloth.
b. While pressing down on the shift lever, 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 W/ CENTER BEARING SHAFT ASSY (ACCESS CAB)
12. REMOVE PROPELLER SHAFT ASSY (REGULAR CAB)
13. REMOVE STARTER ASSY





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





15. SEPARATE CLUTCH RELEASE CYLINDER ASSY
a. Remove the 2 bolts and separate the clutch release cylinder assy.
16. REMOVE FRAME CROSSMEMBER SUB-ASSY NO.3
a. Support the transmission rear side with a transmission jack.





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





17. REMOVE ENGINE MOUNTING INSULATOR REAR NO.1
a. Remove the 4 bolts and engine mounting insulator rear No.1.
18. 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 wire harness clamp from the transmission assy.





19. REMOVE MANUAL TRANSMISSION UNIT ASSY
a. Remove the 7 bolts and remove the transmission assy.





20. INSTALL MANUAL TRANSMISSION UNIT ASSY
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 direction of the front of the vehicle.

21. CONNECT WIRE HARNESS
a. Connect the wire harness clamp to the transmission assy.
b. Connect the back-up lamp switch connector.
c. Connect the speed sensor connector.





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





23. 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.)





24. INSTALL CLUTCH RELEASE CYLINDER ASSY
a. Install the clutch release cylinder assy with the 2 bolts.
Torque: 12 Nm (120 kgf-cm, 9 ft. lbs.)
25. INSTALL STARTER ASSY





26. 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
27. INSTALL PROPELLER W/ CENTER BEARING SHAFT ASSY (ACCESS CAB)
28. INSTALL PROPELLER SHAFT ASSY (REGULAR CAB)
29. INSTALL EXHAUST PIPE ASSY FRONT
30. ADD MANUAL TRANSMISSION OIL
31. ADJUST MANUAL TRANSMISSION OIL
32. 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.)





33. INSTALL 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 clockwise to install.

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





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