2. Refill the flywheel hub cap and coat the flywheel splines with Super Urea Grease (P/N 08798-9002), as it shown on the picture.
3. Install a new O-ring (rubber) onto the drive shaft and place two 14x20mm dowel pins on the flywheel housing.
4. Attach the flywheel securely to the drive shaft, install the starter onto the flywheel housing.
5. Support the transmission with a jack and raise it to the level of the engine.
6. Attach the gearbox to the engine, then insert the mounting bolt into the gearbox housing.
7. Install the gearbox support bracket. Install the long bolt and tighten the nuts and bolt on the support bracket to the required torque. Then tighten the long bolt to the required torque.
8. Install the front right support/bracket.
9. Connect the ATF cooler hoses to the ATF cooler pipes (see below) as indicated in the figure.
10. Install the mounting bolts in the gearbox housing.
11. Remove the jack from under the gearbox and unhook the winch, then remove the winch bracket from the engine.
12. Attach the flywheel to the drive plate with eight bolts and tighten them as follows: Turn the crankshaft as necessary, tightening the bolts crosswise, first half of the required torque, and then completely. After tightening the last bolt, make sure the crankshaft rotates freely.
13. Install the flywheel cover, then the front stiffener.
14. Install rear support/bracket.
15. Install new retaining rings on the ends of the intermediate shaft and the right drive shaft.
16. Install the intermediate shaft.
Note:
- When installing the intermediate shaft into the differential, be careful not to let dust or other foreign matter enter the gearbox.
- Thoroughly clean the areas at the junction of the intermediate shaft and gearbox (differential) solvent or carburetor cleaner and dry with compressed air.
17. Install the rear stiffener.
18. Install the right and left drive shafts.
Note:
- When installing the right drive shaft into the differential, be careful not to allow dust or other foreign matter to enter the gearbox.
- Thoroughly clean the areas at the junction of the right drive shaft and gearbox (differential) solvent or carburetor cleaner and dry with compressed air.
- Fully unscrew the right and left knuckles and insert the right drive shaft into the differential until you feel that its spring clip has entered the side gear. Insert the left drive shaft into the countershaft until you feel the countershaft spring clip engage the left drive shaft.
19. Install the cardan shaft in the transfer case assembly, aligning the marks.
20. Install exhaust pipe A.
21. Install the rear carrier beam.
22. Install the ball joints of the lower suspension arms on both steering knuckles, then tighten the nuts of the ball joints and fix them with cotter pins.
23. Install the front stabilizer links to the lower suspension arms, then tighten the collar nuts.
24. Install a 5mm socket wrench on the tip of the front stabilizer link ball joint pin, then tighten the collar nuts.
25. Install mudguard.
26. Establish a bracket of a cable of a gear change on a transmission.
27. Attach the tip of the shift cable to the control lever. Do not kink the shift cable.
28. Connect the connectors of the input shaft speed sensor, driven pulley speed sensor, engine coolant sensor (EATING), and vehicle speed sensor (VSS), then install the harness clamp bracket.
29. Connect the solenoid harness connector and drive pulley speed sensor connector, then connect the transmission ground cable terminals and install the radiator hose clamp to the transmission hanger bracket.
30. Connect the cables to the starter with the crimp side of the cable lug facing out.
31. Install the distributor.
32. Install the battery base and the battery itself, then secure the battery with the clamp bracket.
33. Fill the gearbox with the recommended transmission fluid (see above).
34. First connect the positive (+) cable then negative (-) battery cable.
35. Adjust the ignition timing.
36. Start the engine. Engage the parking brake and shift the transmission through all ranges three times.
37. Check shift cable adjustment (see below).
38. Check the alignment of the front wheels (see ch. «Front and rear suspension»).
39. Shift the transmission to position P or N and let the engine warm up to normal operating temperature (radiator fan turns on), then turn it off and check the transmission fluid level (see above).
40. When replacing the transmission assembly, clutch assembly, lower valve box assembly, or engine repair, calibrate the clutch control feedback signal in the PCM module memory (see above).
41. Road test (see above).