Page 2329 of 6000
MANUAL TRANSMISSION7B–11
220RW119
Legend
(1) Pressure Plate Assembly
(2) Release Bearing
(3) Wedge Collar
30. Remove the transmission retaining nuts and bolts.
31. Remove the transmission assembly with transfer
case from the vehicle.
NOTE: Remove the transfer case from the transmission
assembly if the transmission disassembly required.
Refer to Transfer Case in Drive Line/Axle section.
Installation
1. Apply a thin coat of molybdenum disulfide grease to
the top gear shaft spline.
2. Slowly operate the transmission jack until the front of
transmission is aligned with the rear of the engine.
The slope of the engine and the transmission must be
the same.
3. Align the top gear shaft spline with the clutch driven
plate spline.
220RS005
4. Install the transmission to the engine.
Tighten the transmission retaining nuts and bolts.
Page 2330 of 6000
7B–12MANUAL TRANSMISSION
(6VE1)
225RW019
Page 2331 of 6000
MANUAL TRANSMISSION7B–13
(4JX1)
225RW020
5. Apply a force of about 113N (26 Ib) to the tip of the
shift fork in the direction of the transmission to engage
the clutch pressure plate and release bearing.
NOTE: A clicking sound is heard when the release
bearing and the tip of the diaphragm spring engage each
other.
Check to see if they are securely engaged by pushing the
tip of the shift fork toward the engine while applying a
force of about 25 N (5.5 lb). If the shift fork will not move,
then they are securely engaged.
220RS006
6. Install three flywheel under cover (6VE1).
Page 2332 of 6000

7B–14MANUAL TRANSMISSION
7. Install the engine rear mount to the transmission case
and tighten the fixing bolts specified torque (6VE1).
Torque: 41 Nꞏm (4.2kgꞏm/30 Ib ft)
8. Install the third crossmember to the frame and tighten
the fixing bolts specified torque.
Torque: 50 Nꞏm (5.1kgꞏm/37 Ib ft)
9. Tighten the engine rear mount nuts specified torque.
Torque: 50 Nꞏm (5.1kgꞏm/37 Ib ft)
10. Remove the transmission jack.
11. Apply the grease to top hole portion of the shift fork.
12. Install the slave cylinder and tighten the fixing bolts
specified torque.
Torque: 43 Nꞏm (4.4kgꞏm/32 Ib ft)
13. Install the clutch dust cover to the clutch housing and
tighten the fixing bolts specified torque.
Torque: 8 Nꞏm (0.8kgꞏm/69 Ib in)
220RS007
14. Install the slave cylinder heat protector to the slave
cylinder.
15. Install bracket and two transmission harness clamps
to the transmission case (6VE1).
16. Install harness heat protector (6VE1).(6VE1)
225RW006
17. Install four fuel pipe bracket (6VE1).
Page 2333 of 6000
MANUAL TRANSMISSION7B–15
141RW024
18. Connect the speedometer sensor and 2WD–4WD
actuator harness connector.
826RW024
Page 2334 of 6000

7B–16MANUAL TRANSMISSION
19. Connect the backup lamp switch, 4WD indicator
switch, and 1-2 indicator switch harness connectors.
826RW023
20. Install the front and 3 way exhaust pipe (6VE1).
Install the exhaust pipe with catalytic converter
(4JX1).
Torque:
Exhaust pipe to exhaust manifold:
67 Nꞏm (6.8 kgꞏm/49 Ib ft)
Exhaust pipe flange bolt:
43 Nꞏm (4.4 kgꞏm/32 Ib ft)
(4JX1)
150RW041
21. Connect two oxygen sensor connectors to the
transmission harness (6VE1).
22. Install the front propeller shaft and tighten the fixing
bolts and nuts specified torque.
Torque: 63 Nꞏm (6.4 kgꞏm/46 Ib ft)
23. Install the rear propeller shaft and tighten the fixing
bolts and nuts specified torque.
Torque: 63 Nꞏm (6.4 kgꞏm/46 Ib ft)24. Install transfer protector and tighten the fixing bolts
specified torque.
Torque: 37 Nꞏm (3.8 kgꞏm/27 Ib ft)
25. Install the transmission control lever and transfer
control lever.
235RW014
26. Install the grommet assembly.
27. Install the front console assembly.
28. Install the gear control lever knob.
29. Connect battery ground cable.
30. Install engine hood.
Page 2335 of 6000
MANUAL TRANSMISSION7B–17
Rear Oil Seal (Transfer Adapter)
Removal
1. Remove the transfer case assembly from the vehicle.
Refer to Transfer Case in Drive Line/Axle section.
2. Remove the rear oil seal from the transfer adapter.
220RW090
Installation
1. Use 5–8840–2558–0 (J–42802) transfer adapter oil
seal installer, and install the rear oil seal to the transfer
adapter.
2. Apply grease to the oil seal lip.
3. Install the transfer case assembly to the vehicle.
Refer to Transfer Case in Drive Line/Axle section.
220RW115
Page 2336 of 6000
7B–18MANUAL TRANSMISSION
Transmission (AR-5)
Disassembled View
226RW182
Legend
(1) Snap Ring
(2) Bearing
(3) Top Gear Shaft
(4) Block Ring
(5) Roller Bearing
(6) Snap Ring
(7) Clutch Hub No.2 Assembly
(8) 3rd Block Ring
(9) 3rd Gear
(10) 3rd Gear Needle Roller Bearing
(11) Mainshaft
(12) Thrust Washer Pin
(13) 2nd Gear Needle Roller Bearing
(14) 2nd Gear
(15) Synchronizer Assembly(16) Clutch Hub No.1 Assembly
(17) Snap Ring
(18) Synchronizer Assembly
(19) 1st Gear
(20) 1st Gear Bearing Spacer
(21) 1st Gear Needle Roller Bearing
(22) 1st Gear Thrust Washer
(23) Mainshaft Bearing
(24) Snap Ring
(25) 5th Gear
(26) Snap Ring
(27) Intermediate Plate
(28) Bearing Retainer
(29) Snap Ring
(30) Front Bearing Assembly
(31) Counter Gear Shaft