Transmission Installation
Installation1. Flush the ATF cooler.
2. Install the torque converter assembly (A) on the mainshaft (B) with a new O-ring (C).
3. Install the 14 mm dowel pins (D) in the torque converter housing (E).
4. Install the starter (F) on the torque converter housing.
5. Place the transmission on a transmission jack, and raise it to engine level.
6. Attach the transmission to the engine, then install the rear mount bracket bolts:
- 12 x 1.25 mm bolts (2) (A) for all models.
- 10 x 1.25 mm bolts (2) (B) for '01-02 models.
7. Install the transmission housing mounting bolts.
8. Face the dot mark (A) on the breather tube (B) up.
9. Install the transmission/mount bracket (C). Tighten the bolt (D) loosely, and tighten the nuts (E) to the specified torque, then tighten the bolt to the specified torque.
10. Remove the transmission jack and hoist bracket.
11. Attach the torque converter to the drive plate (A) with eight bolts (B). Rotate the crankshaft pulley as necessary to tighten the bolts to 1/2 of the specified torque, then to the final torque, in a crisscross pattern. After tightening the last bolt, check that the crankshaft Rotates freely.
12. Tighten the crankshaft pulley bolt as necessary.
13. Install the control lever (C) with the shift cable (D) on the control shaft (E). Do not bend the shift cable excessively.
14. Install the lock bolt (F) with a new lockwasher (G), then bend the lock washer tab against the bolt.
15. Install the engine stiffener (H).
16. Install the shift cable cover (I), then install the shift cable holder (J) on the shift cable cover.
NOTE: To prevent damage to the control lever joint, be sure to install the shift cable holder after installing the shift cable cover to the torque converter housing.
17. Install new set rings on the right and left driveshafts.
18. Install the right and left driveshaft. While installing the driveshaft in the differential, be sure not to allow dust or other foreign particles to enter the transmission.
NOTE:
- Clean the areas where the driveshaft contacts the transmission (differential) with solvent or carburetor cleaner, and dry with compressed air.
- Turn the right and left steering knuckle fully outward, and slide the driveshaft into the differential until you feel its spring clip engage the side gear.
19. Install the front beam (A) by aligning the reference marks (B) on the rear beam (C).
20. Install the front mount bracket bolts.
21. Install the damper forks (A), then install the ball joints on each lower arms (B) with the castle nuts (C) and new cotter pins (D).
22. Install the radius rods (E) on each lower arm.
23. Install the splash shield.
24. Connect the 2nd clutch pressure switch connector (A), and install the rear stiffener (B) ('98-00 models). Do not allow water, fluid, oil, dust, or other foreign particles to get inside the 2nd clutch pressure switch connector.
25. Connect the connectors to the shift solenoid valve B (A) and C (B), and install the clamp (C) on the clamp bracket (D).
26. Connect the ATF cooler hoses (E) to the cooler lines (F).
27. Connect the torque converter clutch solenoid valve/ shift solenoid valve A connector (G).
28. Connect the connector to the countershaft speed sensor (A) and transmission range switch (B), and install the harness clamp and transmission range switch connector on the connector/clamp bracket (D).
29. Install the transmission Ground cable terminal (A).
30. Connect the connectors to the mainshaft speed sensor (B), A/T clutch pressure control solenoid valves A and B (C) and 3rd clutch pressure switch (D), and install the harness clamps (E) on the clamp brackets. Do not allow water, fluid, oil, dust, or other foreign particles to get inside the 3rd clutch pressure switch connector.
31. Install the starter cables (A) with crimped side of the ring terminals facing out.
32. Install the harness clamps (B) on the clamp brackets (C).
33. Install the radiator hose (D) on the clamp (E).
34. Install the breather tube (F) on the clamp (G) with the dot (H) on the tube facing up.
35. Install the battery base.
36. Install the battery cable clamps on the battery base.
37. Install the battery tray and battery, then secure the battery with its hold-down bracket.
38. Install the intake air duct and air cleaner housing assembly.
39. Refill the transmission with ATF.
40. Connect the battery positive terminal, then connect the negative terminal.
41. Set the parking brake. Start the engine, and shift the transmission through all gears three times.
42. Check the shift lever operation, A/T gear position indicator operation, and shift cable adjustment.
43. Check and adjust the front wheel alignment.
44. Start the engine and let it reach normal operating temperature (the radiator fan comes on) with the transmission in P or N position, then turn it off and check the ATF level.
45. Perform a road test.
46. Enter the anti-theft code for the radio, then enter the customer's radio station presets.
47. Loosen the front mount bracket bolt (A) after the road test, then retighten the bolts to the specified