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Removal & Installation: Transmission: Installation

WARNING: This page is about a different variant/trim than selected.
NOTE: Before installing transmission, press clutch release lever toward transmission housing and secure it with an assembly pin, assembly bolt or a M8 x 35 bolt. Remove pin or bolt after transmission has been installed. Hole will then be sealed by 3rd cable support bracket securing bolt. See Figure.
  1. To install, reverse removal procedure. Apply grease to ball stud and inner surface of release bearing. Clean hub splines of input shaft and apply a light coat of grease. Ensure clutch disc slides on input shaft spines.
  2. Check whether dowel sleeves for aligning engine/transmission are fitted in cylinder block, install if necessary. Ensure that intermediate plate is correctly positioned on engine.
  3. Install pressure plate bolts finger tight. Using clutch centering tool (3190A), align clutch disc and pilot bushing holes. Tighten pressure plate bolts to specification using a crosswise pattern. See TORQUE SPECIFICATIONS .
  4. Ensure transmission oil level is correct. Using Flywheel Lock (3067) or similar device, hold crankshaft from turning. Tighten flywheel bolts to specification. See TORQUE SPECIFICATIONS .
  5. Tighten transmission-to-engine bolts to specification. Install NEW hex bolts (arrows B) for left hand assembly mounting in transmission mounting. See Figure. See TORQUE SPECIFICATIONS . Install pendulum support using new bolts for securing. See Figure.
  6. Reconnect exhaust system. Install retainer for power steering line on starter and on transmission.
  7. If removed, install small cover plate (A) behind right-hand drive flange (arrows). See Figure. If removed, install large cover plate for clutch. Fit drive axle shafts to transmission.
  8. If removed, install protective cap for right-hand inner constant velocity joint to engine. Install starter. Install slave cylinder.
    9. NOTE: For vehicle built after May 1999, go to step  14.
  9. On vehicles built before May, 1999, install cable support bracket on transmission (arrows). If necessary push hose onto cable support bracket. See Figure.
  10. Install gear selector cable (B) and balance weight (A) on gear selector lever (vehicles built before May, 1999). Lift tab in direction of arrow and fit gate selector cable on follower/relay lever (C). See Figure.
  11. Attach reverse light connector. Attach all other electrical connections and ground wires to transmission and to engine/transmission securing bolts. Attach connector to speedometer sensor.
  12. Assemble air intake duct. Reconnect ground strap to battery.
  13. Install insulation tray below engine/transmission, if fitted. Install engine cover. Check transmission oil. Adjust gear selector mechanism. See SELECTOR MECHANISM  under ADJUSTMENTS.
  14. On vehicle built after May 1999, fit gear selector cable (B) with transmission selector lever (arrow). See Figure. Fit gate selector cable (A) with relay lever and secure (arrow).
  15. Attach reverse light connector (arrow 2). See Figure. Attach all other electrical connections and ground wires to transmission and to engine/transmission securing bolts. Attach connector to speedometer sensor (arrow 1).
  16. Assemble air intake duct. Reconnect ground strap to battery.
  17. Install insulation tray below engine/transmission, if fitted. Install engine cover. Check transmission oil. Adjust gear selector mechanism. See SELECTOR MECHANISM under ADJUSTMENTS.
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