TRANSMISSION REMOVAL/INSTALLATION [R15M-D]

BHE051101025W03

1. Remove the engine cover.

(See ENGINE COVER REMOVAL/INSTALLATION.)

2. Remove the battery cover.

3. Disconnect the negative battery cable.

4. Drain the transmission oil.

(See TRANSMISSION OIL REPLACEMENT [R15M-D].)

5. Remove in the order indicated in the table.

6. Install in the reverse order of removal.

7. Add the transmission oil.

(See TRANSMISSION OIL REPLACEMENT [R15M-D].)

8. Perform the 'INSPECTION AFTER TRANSMISSION INSTALLATION', and verify that there is no abnormality.

(See INSPECTION AFTER TRANSMISSION INSTALLATION [R15M-D].)

.

1
Shift lever knob
2
Upper panel
3
Shift insulator component (outer)
4
Shift insulator component (inner)
5
Shift lever component
6
Front tunnel member
7
Rear tunnel member
8
HO2S connector
9
HO2S connector bracket
10
Catalytic converter, middle pipe, main silencer
11
Exhaust manifold stay
12
Heat insulator
13
Starter
14
Clutch release cylinder
15
Power plant frame
16
Propeller shaft
17
Back-up light switch connector
18
Neutral switch connector
19
Wire
20
Transmission installation bolt
21
Transmission
22
Stopper
23
Bolt
24
Dynamic damper

Power Plant Frame Removal Note

1. Support the transmission using a transmission jack.

2. Remove the power plant frame.

Propeller Shaft Removal Note

1. Install the SST to the main shaft.

2. Insert a slab of wood behind the differential, and remove the propeller shaft.

Transmission Removal Note

Warning
• Remove the transmission carefully, holding it steady. If the transmission falls it could be damaged or cause injury.
Caution
• To prevent part interference in the engine compartment, position the installation part of the exhaust manifold stay of the front pipe on the transverse member to control the inclination of the transmission under its own weight.

1. Support the transmission securely using a transmission jack.

2. Remove the transmission installation bolts.

3. Remove the transmission.

Transmission Installation Note

1. Shift to any gear position.

2. Install the SST to the main shaft.

Warning
• Remove the transmission carefully, holding it steady. If the transmission falls it could be damaged or cause injury.

3. Place the transmission on the transmission jack and raise it.

Note
• Slowly rotate the SST to engage the clutch with the main drive gear spline, and install the transmission.

4. Install the transmission.

5. Tighten the transmission installation bolts.

Bolt length
A: 55 mm {2.1 in}
B: 90 mm {3.5 in}
Tightening torque
37-52 N·m {3.8-5.3 kgf·m, 28-38 ft·lbf}

Power Plant Frame Installation Note

1. Using a transmission jack, support the transmission so that it is level with the differential.

2. Install the power plant frame.

3. Temporarily tighten the nuts in the order shown in the figure.

4. Tighten nuts 1 until the power plant frame is seated in the differential.

5. Install the heat insulator, exhaust manifold stay, catalytic converter, middle pipe, main silencer, and front tunnel member.

6. Raise the front end of the power plant frame (transmission side) or the transmission with the transmission jack, and adjust dimension A to 55-57 mm {2.16-2.24 in} (lower surface of power plant frame-lower surface of the front tunnel member) as shown in the figure.

Note
• When a transmission jack or similar device is not used for raising the power plant frame, tighten a bolt with a length of 55 mm {2.16 in} or more (M12x1.25) from the underside of the front tunnel member as shown in the figure to raise the power plant frame.
• When using a bolt, attach tape or other material at the bottom surface of the power plant frame to protect it from damage.

7. Tighten the nuts and bolts on the rear differential side in the order shown in the figure.

N·m {kgf·m, ft·lbf}

Bolt, nut number

Tightening torque

1, 2

126.0-154.0

{12.9-15.7, 93.0-113}

3

74.5-93.2

{7.60-9.50, 55.0-68.7}

8. Tighten the nuts on the rear differential side in the order shown in the figure.

Tightening torque
126.0-154.0 N·m
{12.9-15.7 kgf·m, 93.0-113 ft·lbf}

9. Verify that dimension A is within the specification with the transmission jack and the adjustment bolt removed.

• If it is not within the specification, adjust dimension A again.
Standard dimension A
48.4-56.4 mm {1.91-2.22 in}

Shift Lever Component Installation Note

Note
• If the extension housing has been removed or the transmission has been disassembled and inspected, always add the specified type and amount of transmission oil.

1. Add the specified type and amount of oil to the shift control case.

Specified oil
API GL-4 or GL-5
All season: SAE 75W-90
Above 10°C {50°F}: SAE 80W-90
Capacity (approx. quantity)
290-320 ml {17.7-19.5 cu in}

2. Verify that the oil is filled to near the top of the rod in the shift control case.

3. Apply grease to the areas of the shift lever component as shown in the figure.

4. Align the shift lever component notch with the shift control case pin and install the shift lever component.