Installation

Manual Transmission Removal and Installation

Installation

1. Release Fork

1. Apply super high temp urea grease (P/N 08798-9002) to the release fork (A), the release fork bolt (B), the release bearing (C), and the release bearing guide (D) in the shaded areas.

NOTE: Do not use silicone grease.

2. Set the release fork set spring (E).

NOTE: Replace the release fork bolt if necessary.

3. With the release fork (A) slid between the release bearing pawls (B), install the release bearing on the mainshaft while inserting the release fork through the hole (C) in the clutch housing.

4. Align the detent (D) of the release fork with the release fork bolt (E).

5. Press the detent of the release fork over the release fork bolt squarely.

6. Install the release fork boot (F).

7. Make sure the boot seals around the release fork and the clutch housing.

8. Move the release fork (A) right and left to make sure that it fits properly against the release bearing (B) and that the release bearing slides smoothly.

NOTE: Wipe off any excess grease.

2. Stud Bolt

1. Install new stud bolts (A).

3. Manual Transmission Assembly

1. Make sure the two dowel pins (A) are undamaged and installed in prescribed holes on the engine block as shown. Replace the dowel pins if they are damaged.

2. Place the transmission on the transmission jack, and raise it to the engine level.

3. Align the transmission mainshaft and the clutch pressure plate.

4. Move the transmission inward until there is no clearance between the transmission housing and the engine block.

Front side

Rear side

5. Install the lower transmission mounting bolts.

6. Install the clutch cover (A).

4. Subframe Support

1. Using the subframe adapter, raise the front subframe up to the body.

5. Front Subframe Assembly

1. Loosely install the new front subframe mounting bolts (A).

2. Insert the subframe alignment pin (B) through the positioning hole (C) on the right front subframe, and into the positioning hole (D) on the body, then loosely tighten the subframe right front mounting bolt.

3. Insert the subframe alignment pin through the positioning slot on the left front subframe, and into the positioning hole on the body, then loosely tighten the subframe left front mounting bolt.

4. Tighten the subframe mounting bolts to the specified torque values starting with the right front subframe mounting bolt. Use the subframe alignment pin when tightening the front side subframe mounting bolts.

5. Check all of the subframe mounting bolts, and retighten if necessary.

NOTE: Tighten the bolts in the sequence shown.

6. Remove the transmission jack and the subframe adapter.

7. Connect the EPS connectors.

8. Tighten the new mid-stiffener mounting bolt on both sides.

6. Lower Torque Rod - Reconnection

1. Install the new lower torque rod mounting bolts.

7. Intermediate Shaft Assembly

1. Clean the areas where the intermediate shaft contacts the differential thoroughly with solvent.

NOTE: Do not wash the rubber parts with solvent.

2. Dry the areas where the intermediate shaft contacts the differential thoroughly with compressed air.

3. Insert the intermediate shaft (A) into the differential correctly.

NOTE: Insert the intermediate shaft carefully to prevent damaging the oil seal (B).

4. Install the flange bolt (A) and the dowel bolts (B).

5. Install the crankshaft position (CKP) sensor cover (A).

8. Driveshaft Front Both Inboard Side

Left driveshaft

1. Install a new set ring (A).

2. Clean the area where the driveshaft contact the differential thoroughly with solvent.

NOTE: Do not wash the rubber parts with solvent.

3. Dry the area where the driveshaft contact the differential thoroughly with compressed air.

4. Insert the inboard end (B) of the driveshaft into the differential (C) until the set ring (D) lock in the groove (E).

NOTE: Insert the driveshaft horizontally to prevent damaging the oil seal.

Right driveshaft

5. Install a new set ring (A).

6. Apply 0.5-1.0 g (0.018-0.035 oz) of super high temp urea grease (P/N 08798-9002) to the whole splined surface (B) of the right driveshaft.

7. After applying grease, remove the grease from the splined grooves at intervals of 2-3 splines and from the set ring groove (C) so that air can bleed from the intermediate shaft.

8. Insert the inboard end (D) of the driveshaft into the intermediate shaft (E) until the set ring (F) lock in the groove (G).

9. Lower Arm Joint - Reconnection, Both Knuckle Side

1. Connect the lower arm to the knuckle on both sides using new flange bolt and new self-locking nuts.

2. After lightly tightening all three fasteners, tighten them to the specified torque in the following order; the nut on the front (B), the nut on the rear (C), then the bolt (D).

10. Tie-Rod End Ball Joint - Connection, Both Side

1. Wipe off any grease contamination from the ball joint tapered section and threads.

2. Connect the tie-rod ball joint (A) to the knuckle.

3. Install the nut (B).

4. Install a new cotter pin (C).

NOTE: Bend the cotter pin as shown.

11. Front Stabilizer Ball Joint, Both Damper Side - Reconnection

1. Connect the stabilizer link (A) on both sides.

2. Install a new flange nut (B) on both sides while holding the joint pin (C) with a hex wrench (D).

12. Front Wheel

1. Install both front wheels.

NOTE: Before installing the wheel, clean the mating surfaces between the brake disc and the inside of the wheel.

13. MTF Replacement (M/T)

1. Remove the filler plug (A) and the sealing washer (B).

2. Refill the transmission with MTF to the proper level (C). Always use Honda Manual Transmission Fluid (MTF).

3. Reinstall the filler plug with a new sealing washer.

14. Splash Shield

1. Install the splash shield (A).

15. Lower The Vehicle On The Lift

1. Lower the vehicle on the lift.

16. Steering Joint - Reconnection

1. Set the rack in the straight ahead driving position.

2. Slip the lower end of the steering joint (A) onto the pinion shaft (B).

NOTE:
* Pinion shaft with center guide: Install the steering joint by aligning the center guide (C).
* Pinion shaft without center guide: Position the steering column by aligning the gap (D) within the angle.

3. Align the bolt hole (A) on the steering joint with the groove (B) around the pinion shaft.

4. Loosely install the steering joint bolt (C).

5. Be sure that the joint bolt is securely in the groove in the pinion shaft.

6. Pull on the steering joint to make sure that the steering joint is fully seated.

17. Steering Wheel Release

1. Remove the steering wheel holder tool (A).

18. Steering Joint Bolt - Tighten

1. Tighten the steering joint bolt (A) to the specified torque.

19. Steering Column Lower Slide Shaft - Release

1. Cut the wire (A).

20. Steering Joint Cover

1. Install the steering joint cover (A) in the sequence shown.

21. Transmission Mount Assembly

1. Install the transmission mount assembly (A) using new bolts and new nuts.

2. Install the ground cable terminal (B).

22. Upper Transmission Housing Mounting Bolt

1. Install the upper transmission mounting bolts.

23. Engine Support Hanger

1. Remove the engine support hanger.

2. Remove the universal lifting eyelet.

24. Transmission Peripheral Assembly Upper Side

1. Install transmission hanger C.

2. Install the harness clamp (A).

3. Connect the connectors (A).

4. Install the harness clamps (B).

25. Shift Cable Bracket

1. Apply a light coat of silicone grease (P/N 08C30- B0234M) to the shift cable ends (A).

NOTE: Make sure not to get any silicone grease on the terminal part of the connectors and switches, especially if you have silicone grease on your hands or gloves.

2. Connect the shift cable ends to the change lever assembly (B).

3. Install the shift cable bracket (C).

4. Install the lock pins (D).

26. Clutch Slave Cylinder

1. Apply a light coat of super high temp urea grease (P/N 08798-9002) to the push rod (A) of the slave cylinder (B).

2. Install the slave cylinder.

3. Install the clutch line bracket (C).

NOTE: Be careful not to bend the clutch line.

27. ECM Assembly

1. Connect ECM connectors A, B, and C.

NOTE: ECM connectors A, B, and C have symbols (A=(square), B=(triangle), C=(circle)) embossed on them for identification.

2. Install the ECM (D).

3. Install the cover (A).

28. Intake Air Duct

1. Install the intake air duct.

29. Air Cleaner Assembly

1. Install the air cleaner (A).

2. Install the harness clamp (B).

3. Connect the intake air pipe (C) and the intake air duct (D).

30. Battery Terminal - Reconnection

NOTE: If the battery performs abnormally, test the battery.

1. Clean the battery terminals.

2. Connect the positive cable (A) to the battery.

NOTE: Always connect the positive side first.

3. Connect the negative cable and battery sensor (B) to the battery.

4. Apply multipurpose grease to the terminals to prevent corrosion.

31. Under Cowl Panel

1. Install the under cowl panel (A).

32. Center Cowl Cover

1. If necessary, install the hood rear seal (A).

2. Connect the windshield washer tube (B).

3. Install the center cowl cover (C).

33. Both Side Cowl Covers

1. Install the side cowl cover (A).

2. The left side is shown; repeat on the right side.

34. Wiper Arm Assembly

NOTE: Set the wiper arms to the auto-stop position before installation.

1. Install the wiper arms (A).

2. Install the cowl top wiper covers (B).

35. Manual Transmission After Install - Check

1. Check the shift lever operation.

2. Check the clutch operation.

36. Pre-Alignment Checks

For proper inspection and adjustment of the wheel alignment, do these checks:

1. Release the parking brake to avoid an incorrect measurement.

2. Make sure the suspension is not modified.

3. Make sure the fuel tank is full, and that the spare tire, the jack, and the tools are in place on the vehicle.

4. Check the tire size and tire pressure according to tire information.

37. Caster - Inspection

Use commercially available computerized four wheel alignment equipment to measure wheel alignment (caster, camber, toe, and turning angle). Follow the equipment manufacturer's instructions.

1. Check the caster angle.

* If the measurement is within specifications, measure the front camber angle.
* If the measurement is not within specifications, check for bent or damaged suspension components.

38. Camber - Inspection

Use commercially available computerized four wheel alignment equipment to measure wheel alignment (caster, camber, toe, and turning angle). Follow the equipment manufacturer's instructions.

1. Check the camber angle.

* If the measurement is within specification, measure the toe-in.
* If the measurement for the front camber is not within the specification, go to front camber adjustment.
* If the measurement for the rear camber is not within the specification, check for bent or damaged suspension components.

39. Front Toe - Inspection

Use commercially available computerized four wheel alignment equipment to measure wheel alignment (caster, camber, toe, and turning angle). Follow the equipment manufacturer's instructions.

1. Set the steering column to the middle tilt position and telescopic positions.

2. Center the steering wheel spokes, and install a steering wheel holder tool.

3. Check the toe with the wheels pointed straight ahead.

Front toe-in: 0±2 mm (0±0.08 in)
* If adjustment is required, go to the front toe adjustment.
* If no adjustment is required, remove the alignment equipment.

40. Turning Angle - Inspection

Use commercially available computerized four wheel alignment equipment to measure wheel alignment (caster, camber, toe, and turning angle). Follow the equipment manufacturer's instructions.

1. Turn the wheel right and left while applying the brake, and measure the turning angle of both wheels.

2. If the measurement is not within the specifications, even up both sides of the tie-rod threaded section length while adjusting the front toe.

3. If it is correct, but the turning angle is not within the specifications, check for bent or damaged suspension components.

41. HDS DLC - Connection

1. Connect the HDS to the data link connector (DLC) (A) located under the driver's side of the dashboard.

2. Turn the ignition switch to ON (II).

3. Make sure the HDS communicates with the vehicle. If it does not communicate, go to the DLC circuit troubleshooting.

42. VSA Sensor Neutral Position - Memorization

1. Park the vehicle on a flat and level surface, with the steering wheel in the straight ahead position.

2. Select VSA ADJUSTMENT, then select ALL SENSORS with the HDS, and follow the screen prompts.

NOTE: See the HDS Help menu for specific instructions.

43. Steering Angle Sensor Neutral Position - Clear

1. Select EPS ADJUSTMENT, then select EPS STEERING ANGLE SENSOR VALUE CLEAR and follow the screen prompts on the HDS.

NOTE: See the HDS Help menu for specific instructions.

44. Maintenance Minder Reset

1. After doing all procedures, select the individual maintenance item you wish to reset with the HDS (See the Maintenance Minder General Information).