MT2–8

R150F MANUAL TRANSMISSION – ASSEMBLY REMOVAL AND INSTALLATION

ASSEMBLY REMOVAL AND

INSTALLATION
 MT2–9
R150F MANUAL TRANSMISSION – ASSEMBLY REMOVAL AND INSTALLATION

TRANSMISSION REMOVAL
1. DISCONNECT NEGATIVE(–) TERMINAL CABLE
FROM BATTERY
2. REMOVE FAN SHROUD SET BOLTS
Remove the 4 bolts.

3. REMOVE HEATER HOSE CLAMP

(a) Loosen the clamp bolt.
(b) Move the clamp upside.

4. REMOVE TRANSMISSION SHIFT LEVER FROM

INSIDE OF VEHICLE
(a) Remove the 4 screws and shift lever boot retainer.
(b) Pull up the shift lever boot.
(c) Cover the shift lever cap with a cloth.
(d) Then, pressing down on the shift lever cap, rotate it
counterclockwise to remove.
(e) Remove the shift lever.

5. REMOVE TRANSFER SHIFT LEVER FROM INSIDE

OF VEHICLE
Using pliers, remove the snap ring and pull out the
shift lever from the transfer.
6. RAISE VEHICLE AND DRAIN TRANSMISSION AND
TRANSFER OIL
NOTICE: Be sure the vehicle is securely supported.

7. REMOVE PROPELLER SHAFT DUST COVER SUB–

ASSEMBLY
Remove the 3 bolts and cover.
MT2–10
R150F MANUAL TRANSMISSION – ASSEMBLY REMOVAL AND INSTALLATION

8. DISCONNECT FRONT AND REAR PROPELLER

SHAFT
(See page PR–7)
9. DISCONNECT, SPEEDOMETER CABLE, BACK–UP
LIGHT SWITCH CONNECTOR AND TRANSFER IN–
DICATOR SWITCH CONNECTOR

10. REMOVE EXHAUST PIPE, BRACKET AND CLAMP

(a) Remove the exhaust pipe clamp.
(b) Remove the 2 bolts and exhaust pipe bracket from the
clutch housing.
(c) Remove the 3 nuts, exhaust pipe and gasket from the
exhaust manifold.
(d) Remove the 2 bolts and gasket, disconnect the ex-
haust pipe from the catalytic converter front side.

11. REMOVE CLUTCH RELEASE CYLINDER

Remove the 2 bolts and lay the release cylinder along-
side the engine.
HINT: Do not disconnect the clutch line.
12. REMOVE FRONT DIFFERENTIAL SET BOLTS
(a) Remove the 3 bolts.
(b) Support the front differential.

13. REMOVE STABILIZER BAR BRACKET SET BOLTS

Remove the 4 bolts.
 MT2–11
R150F MANUAL TRANSMISSION – ASSEMBLY REMOVAL AND INSTALLATION

14. REMOVE NO. 2 FRAME CROSSMEMBER FROM

SIDE FRAME
(a) Remove the 4 bolts from the engine rear mounting.
(b) Using a transmission jack, support the transmission.
(c) Remove the 8 bolts and No. 2 frame crossmember
from the side frame.

15. LOWER TRANSMISSION WITH TRANSFER

16. REMOVE STARTER
(a) Remove the 2 bolts and starter.
(b) Lay the starter alongside the engine.
17. REMOVE EXHAUST PIPE BRACKET AND STIFF–
ENER PLATE BOLTS
18. REMOVE REMAINING TRANSMISSION BOLTS
19. REMOVE TRANSMISSION WITH TRANSFER
Remove the transmission with the transfer toward the
rear of the vehicle.
20. REMOVE ENGINE REAR MOUNTING
Remove the 4 bolts and engine rear mounting from the
transfer.

21. REMOVE PROPELLER SHAFT UPPER DUST COVER

AND TRANSFER FROM TRANSMISSION
(a) Remove the dust cover bolt from the bracket.
(b) Remove the transfer adaptor rear mounting bolts.

(c) Pull the transfer straight up and remove it from the

transmission.
HINT: Take care not to damage the adaptor rear oil seal
with the transfer input gear spline.
MT2–12
R150F MANUAL TRANSMISSION – ASSEMBLY REMOVAL AND INSTALLATION

TRANSMISSION INSTALLATION
1. INSTALL TRANSFER AND PROPELLER SHAFT
UPPER DUST COVER TO TRANSMISSION WITH
NEW GASKET
(a) Shift the 2 shift fork shafts to the high–4 position.

(b) Apply MP grease to the adaptor oil seal.

(c) Place a new gasket to the transfer adaptor.
(d) Install the transfer to the transmission.
HINT: Take care not to damage the oil seal by the in-
put gear spline when installing the transfer.

(e) Install and torque the bolts with the propeller shaft up-
per dust cover.
Torque: 37 N–m (380 kgf–cm, 27 ft–lbf)

(f) Install the dust cover bolt to the bracket.

Torque: 23 N–m (230 kgf–cm, 17 ft–lbf)

2. INSTALL ENGINE REAR MOUNTING

Install the engine rear mounting and torque the 4
bolts.
Torque: 25 N–m (260 kgf–cm, 19 ft–lbf)
 MT2–13
R150F MANUAL TRANSMISSION – ASSEMBLY REMOVAL AND INSTALLATION

3. PLACE TRANSMISSION WITH TRANSFER AT IN–

STALLATION POSITION
(a) Support the transmission with a jack.
(b) Align the input shaft spline with the clutch disc, and
push the transmission with the transfer fully into
position.

4. INSTALL TRANSMISSION, STIFFENER AND STA–

RTER BOLTS
Torque:
(A) Transmission bolt:
72 N–m (730 kgf–cm, 53 ft–lbf)
(B) Stiffener plate bolt:
37 N–m (380 kgf–cm, 27 ft–lbf)
(C) Starter bolt:
39 N–m (400 kgf–cm, 29 ft–lbf)
5. INSTALL NO. 2 FRAME CROSSMEMBER
(a) Raise the transmission slightly with a jack.
(b) Install the No. 2 frame crossmember to the side frame
and torque the 8 bolts.
Torque: 95 N–m (970 kgf–cm, 70 ft–lbf)
(c) Lower the transmission and transfer.
(d) Install the 4 mounting bolts to the engine rear mount–
ing. Torque the bolts.
Torque: 13 N–m (130 kgf–cm, 9 ft–lbf)

6. INSTALL STABILIZER BAR BRACKET SET BOLTS

Install and torque the 4 bolts.
Torque: 29 N–m (300 kgf–cm, 22 ft–lbf)

7. INSTALL FRONT DIFFERENTIAL ASSEMBLY

Install and torque the 3 bolts.
Torque:
Differential carrier cover to frame:
147 N–m (1,500 kgf–cm, 108 ft–lbf)
Others:
167 N–m (1,700 kgf–cm, 123 ft–lbf)
MT2–14
R150F MANUAL TRANSMISSION – ASSEMBLY REMOVAL AND INSTALLATION

8. INSTALL EXHAUST PIPE, BRACKET AND CLAMP

(a) Install a new gasket and the exhaust pipe to the
manifold. Torque 3 new nuts.
Torque: 62 N–m (630 kgf–cm, 46 ft–lbf)
(b) Install the exhaust pipe bracket to the clutch housing
and torque the 2 bolts.
Torque: 39 N–m (400 kgf–cm, 29 ft–lbf)
(c) Install the exhaust pipe clamp.
Torque: 19 N–m (195 kgf–cm, 14 ft–lbf)

(d) Install the exhaust pipe and a new gasket to the cata-
lytic converter front side. Torque the 2 bolts.
Torque: 39 N–m (400 kgf–cm, 29 ft–lbf)

9. INSTALL CLUTCH RELEASE CYLINDER

Install the clutch release cylinder and torque the 2
bolts.
Torque: 12 N–m (20 kgf–cm, 9 ft–lbf)

10. INSTALL PROPELLER SHAFT DUST COVER SUB–

ASSEMBLY
(a) Install the cover.
(b) Install and torque the 3 bolts.
Torque:
Bolt A: 36 N–m (370 kgf–cm, 27 ft–lbf)
Bolt B: 23 N–m (230 kgf–cm, 17 ft–lbf)

11. CONNECT SPEEDOMETER CABLE, BACK – UP

LIGHT SWITCH CONNECTOR AND TRANSFER IN–
DICATOR SWITCH CONNECTOR
12. CONNECT FRONT AND REAR PROPELLER SHAFT
(See page PR–16)
 MT2–15
R150F MANUAL TRANSMISSION – ASSEMBLY REMOVAL AND INSTALLATION

13. FILL TRANSMISSION WITH GEAR OIL

Oil grade:
API GL–3, GL–4 or GL–5
Viscosity:
SAE 75W–90
Capacity:
2.2 liters (2.3 US qts, 1.9 Imp. qts)
14. LOWER VEHICLE

15. INSTALL TRANSFER SHIFT LEVER

(a) Apply MP grease to the transfer shift lever.
(b) Install the shift lever, as shown.
(c) Using pliers, install the snap ring.

16. INSTALL TRANSMISSION SHIFT LEVER

(a) Apply MP grease to the transmission shift lever.
(b) Align the groove of the shift lever cap and the pin part
of the case cover.
(c) Cover the shift lever cap with a cloth.
(d) Then, pressing down on the shift lever cap, rotate it
clockwise to install.

17. INSTALL HEATER HOSE CLAMP

(a) Move the clamp to correct position.
(b) Torque the clamp bolt.

18. INSTALL FAN SHROUD SET BOLTS

Install and torque the 4 bolts.
19. CONNECT NEGATIVE (–) TERMINAL CABLE TO
BATTERY
20. PERFORM ROAD TEST
Check for abnormal noises and smooth shifting.