Manual Transmission Installation

Manual Transmission Installation

Special Tools Required

- Universal Lifting Eyelet 07AAK-SNAA120
- Engine Support Hanger, A and Reds AAR-T1256
- Engine Hanger Adapter VSB02C000026
*: Available through the Honda Tool and Equipment Program 888-424-6857.

NOTE: Use fender covers to avoid damaging painted surfaces.

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. Check the release bearing, and reinstall the release bearing and the release fork with specified grease.

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

4. Align the transmission mainshaft and the clutch pressure plate, then move the transmission inward until there is no gap between the transmission housing and the IMA motor housing.

5. Install the lower transmission housing mounting bolts.

Front side





Rear side





6. Install the torque rod bracket (A) with a new bolt (B) and bolts (C).





7. Install the intermediate shaft Intermediate Shaft Installation.

8. Install both driveshafts Driveshaft Installation.

9. Set the front subframe (A) with the steering gearbox on the transmission jack and support it.





10. Carefully raise the front subframe with the transmission jack, and pass the pinion shaft into the passenger's compartment.

NOTE:

- Be sure that the pinion shaft grommet (B) is in place securely. Make sure the pinion shaft grommet is not turned up. Incorrect installation can cause leakage of water or mud, and noise.
- Take care not to damage the lower arm ball joint boot with the edge of the knuckle, etc.

11. Loosely tighten new front subframe mounting bolts (C). Align the front subframe Service and Repair, then tighten the bolts to the specified torque.

12. Install the torque rod (A). Install the bolt with the tab (B) on the bolt head aligned with the guide (C) on the front subframe, then loosely tighten a new torque rod mounting bolt (D) and a new nut (E).

NOTE: Make sure to set "UP" mark of the torque rod to upper side when you install it.






13. Install the secondary HO2S wire (A) to the clamp (B).






14. Pull down the lever (A) of the EPS motor 3P connector (B), then confirm the connector is fully seated. Connect the EPS motor angle sensor 8P connector (C) and torque sensor 6P connector (D) to the steering gearbox.





15. Connect the lower arm ball joints to the knuckles.

16. Connect the tie-rod end ball joints to the knuckles.

17. Connect the stabilizer links to the stabilizer bar Service and Repair.

18. Lower the vehicle.

19. Install the upper transmission housing mounting bolts (A).






20. Install the transmission mount bracket (A) with the transmission mount bracket base (B).





21. Loosely tighten new transmission mount bolt (C) and the transmission mount bracket base bolts (D), then install the ground cable (E).

22. Remove the engine support hanger (AAR-T1256) and the universal lifting eyelet from the engine.

23. Loosen and retighten the side engine mount/bracket assembly mounting nuts (A).






24. Tighten the transmission mount bracket bolt and the transmission mount bracket base bolts in the numbered sequence shown.





25. Raise the vehicle on a lift, and make sure it is securely supported.

26. Tighten the torque rod mounting bolt and nut in the numbered sequence shown.





27. Lower the vehicle.

28. Connect the steering joint onto the steering gearbox pinion shaft, then install the steering joint cover Steering Gearbox Removal/Installation.

29. Install the ECM bracket (B) with the ECM to the body.





30. Install the harness clips (C) to the ECM bracket, then install auxiliary under-hood relay box A.

31. Install the ECM bracket mount bolts (D).





32. 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.

33. Install the ECM cover (E).

34. Connect the output shaft (countershaft) speed sensor 3P connector (A).






35. Connect the back-up light switch 2P connector (A).





36. Connect the neutral position switch 2P connector (B) and the harness bracket (C).

37. Install the starter Removal and Replacement.

38. Connect the reverse lockout solenoid 2P connector (A).





39. Apply a light coat of silicone grease (P/N 08C30-B0234M) to the cable ends (B), and connect the cable end to the change lever assembly (C), then install the shift cable bracket (D), the harness bracket (E), and the lock pins (F). Do not bend or damage the shift cables.

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.

40. Apply a light coat of super high temp urea grease (P/N 08798-9002) to the end of the slave cylinder push rod (A). Install the slave cylinder (B). Be careful not to bend the clutch line.






41. Install the cable guard bracket (A) and the clutch line bracket (B).






42. Connect the IMA motor power cable connector (A), then install the harness clamp (B).

NOTE: Make sure you have the IMA system service precautions High Voltage Safety.





43. Install the air cleaner Service and Repair.

44. Do the 12 volt battery installation procedure Removal and Replacement.

45. Install the front bumper center upper beam Front Bumper Center Upper Beam Replacement.

46. Refill the transmission fluid to the proper level Service and Repair.

47. Install the splash shield Splash Shield Replacement.

48. Turn the battery module switch ON.

49. Do the ECM reset procedure.

50. Check the wheel alignment, and adjust it if necessary Service and Repair.

51. Check the shift lever and the clutch operation.

52. Test-drive the vehicle.