Transmission Replacement

MANUAL TRANSMISSION UNIT ASSY (RA60)








COMPONENTS

REPLACEMENT
1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL
2. REMOVE CONSOLE PANEL UPPER REAR
3. REMOVE CONSOLE BOX ASSY REAR
4. REMOVE SHIFT LEVER KNOB SUB-ASSY
5. REMOVE CONSOLE BOX FRONT





6. REMOVE SHIFT LEVER BOOT ASSY
a. Remove the 2 screws and 2 clips, then remove the shift lever boot.





7. REMOVE FLOOR SHIFT SHIFT LEVER ASSY
a. Separate the shift lever cap boot from the manual transmission.





b. Cover the shift lever cap with a cloth.
c. Pressing down on the shift lever cap, turn it counterclockwise to remove the shift lever.
d. Pull out the shift lever.
8. REMOVE ENGINE UNDER COVER NO. 2 (W/ ENGINE UNDER COVER NO.2)
9. DRAIN MANUAL TRANSMISSION OIL
a. Remove the drain plug, gasket and then drain the manual transmission oil.
b. Install a new gasket and the drain plug.
Torque: 37 Nm (377 kgf-cm, 27 ft. lbs.)
10. REMOVE EXHAUST PIPE ASSY
11. REMOVE PROPELLER W/ CENTER BEARING SHAFT ASSY





12. REMOVE MANIFOLD STAY NO.2
a. Remove the 3 bolts and manifold stay No.2.





13. REMOVE MANIFOLD STAY
a. Remove the 3 bolts and manifold stay.
14. REMOVE STARTER ASSY
15. REMOVE CLUTCH HOUSING COVER NO.1
16. REMOVE CLUTCH RELEASE CYLINDER ASSY
17. REMOVE CLUTCH ACCUMULATOR ASSY
18. SUPPORT MANUAL TRANSMISSION UNIT ASSY
a. Support the manual transmission with a transmission jack.





19. REMOVE FRAME CROSSMEMBER SUB-ASSY NO.3
a. Remove the 4 bolts on the frame crossmember sub-assembly No.3.
b. Remove the 4 nuts, 4 bolts and frame crossmember subassembly No.3.





20. REMOVE ENGINE MOUNTING INSULATOR REAR NO.1
a. Remove the 4 bolts and the engine mounting insulator rear No.1.
21. DISCONNECT CONNECTOR
a. Tilt down the transmission.
b. Disconnect the speedometer sensor connector.
c. Disconnect the back up lamp switch connector.
22. DISCONNECT WIRE HARNESS





23. REMOVE MANUAL TRANSMISSION UNIT ASSY
a. Remove the 9 bolts.
b. Separate and remove the manual transmission.





24. REMOVE MANUAL TRANSMISSION CASE COVER
a. Remove the 5 bolts and manual transmission case cover.





25. INSTALL MANUAL TRANSMISSION CASE COVER
a. Install the manual transmission case cover with the 5 bolts.
Torque: 12 Nm (117 kgf-cm, 8.5 ft. lbs.)





26. INSTALL MANUAL TRANSMISSION UNIT ASSY
a. Install the manual transmission with the 9 bolts.
Torque:
72 Nm (730 kgf-cm, 53 ft. lbs.) for bolt A
37 Nm (380 kgf-cm, 28 ft. lbs.) for bolt B
27. INSTALL WIRE HARNESS





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





29. INSTALL FRAME CROSSMEMBER SUB-ASSY NO.3
a. Install the frame crossmember sub-assembly No.3 with the 4 bolts and 4 nuts.
Torque: 40 Nm (408 kgf-cm, 30 ft. lbs.)
b. Install the frame crossmember sub-assembly No.3 with the 4 bolts.
Torque: 19 Nm (189 kgf-cm, 14 ft. lbs.)
30. INSTALL CLUTCH ACCUMULATOR ASSY
31. INSTALL CLUTCH RELEASE CYLINDER ASSY
32. INSTALL CLUTCH HOUSING COVER NO.1
33. INSTALL STARTER ASSY





34. INSTALL MANIFOLD STAY
a. Install the manifold stay with the 3 bolts.
Torque: 40 Nm (408 kgf-cm, 30 ft. lbs.)





35. INSTALL MANIFOLD STAY NO.2
a. Install the manifold stay No.2 with the 3 bolts.
Torque: 40 Nm (408 kgf-cm, 30 ft. lbs.)
36. INSTALL PROPELLER W/ CENTER BEARING SHAFT ASSY
37. INSTALL EXHAUST PIPE ASSY
38. ADD MANUAL TRANSMISSION OIL
39. ADJUST MANUAL TRANSMISSION OIL
40. INSTALL ENGINE UNDER COVER NO. 2 (W/ ENGINE UNDER COVER NO.2)





41. INSTALL FLOOR SHIFT SHIFT LEVER ASSY
a. Apply MP grease to the tip of the shift lever.





b. Cover the shift lever cap with a cloth.
c. Pressing down on the shift lever cap, turn it clockwise to install the shift lever.
42. INSTALL SHIFT LEVER BOOT ASSY
a. Install the shift lever boot with the 2 screws and 2 clips.
43. INSTALL CONSOLE BOX FRONT
44. INSTALL SHIFT LEVER KNOB SUB-ASSY
45. INSTALL CONSOLE BOX ASSY REAR
46. INSTALL CONSOLE PANEL UPPER REAR
47. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
Torque: 3.9 Nm (40 kgf-cm, 35 inch lbs.)