Installation

INSTALLATION




1. Install the dowel pins.




2. Apply grease to the parts as shown, then install the release bearing and release fork.

NOTE: Use only Super High Temp Urea Grease (P/N 08798-9002).

3. Install the release fork boot.
4. Place the transmission on the transmission jack, and raise it to the engine level.




5. Install the 3 lower transmission mounting bolts.




6. Install the 2 upper transmission mounting bolts.




7. Raise the transmission, then install the mount bracket and transmission mount.

NOTE: Torque mounting bolts and nuts in sequence shown.

CAUTION: Make sure the bushings are not twisted or offset.




8. Install the 3 bracket mounting bolts.




9. Install the rear beam stiffener.




10. Install the intake manifold stay.




11. Install the clutch cover.




12. Install the center beam.




13. Install the intermediate shaft and driveshafts. Drive Axles, Bearings and Joints




14. Install the radius rod.

NOTE: Check for deterioration or damage of the radius rod rubber bushings.

15. Install the boll joint to the lower arm.
16. Install the damper fork.




17. Install the rear engine mount bracket stay.

NOTE: Loosely install the stay mounting bolt and nut, then torque in the sequence shown.




18. Install the clutch damper.




19. Install the slave cylinder, then install the clutch pipe joint and stay.

CAUTION: Take care not to bend the pipe.




20. Install the speed sensor, then connect the connector.




21. Install the shift cable and select cable to the shift arm lever and to select lever respectively.

CAUTION: Take care not to bend the cables.

NOTE: Check that the new cotter pin is seated firmly.




22. Connect the transmission ground cable and back-up light switch connectors.
23. Install the harness clamp.
24. Install the starter motor, then connect the cables.




25. Install the bracket and vacuum tank.




26. Install the air cleaner case and air flow tube.




27. Install the base stay and battery base.
28. Refill the transmission with oil.
29. Install the battery, then connect the battery negative (-) and positive (+) cables to the battery.
30. Check the clutch operation.
31. Shift the transmission and check for smooth operation.




32. Loosen the 3 mount bolts of the front engine mount bracket, then torque the 3 mount bolts.

CAUTION: Make sure the bushings are not twisted or offset.