Gearbox (page 11 of 11)

16. Ensure selector linkage and shaft are clean, fit linkage to shaft and secure with new roll pin.
17. Fit clip to retain roll pin.
18. Clean gear change linkage and cable sockets.
19. Fit gear change cables to abutment brackets and fit NEW clips.
20. Apply grease to cable socket.
21. Fit cables to linkage.
22. Fit silencer heat shield. See MANIFOLD & EXHAUST SYSTEMS, Repairs.
23. Fit LH engine mounting to gearbox and and tighten bolts to 48 Nm.
24. With gearbox raised clear of subframe, fit the resonator but do not fit bolts at this stage.
25. Fit buttress and tighten bolts to 45 Nm.
26. Fit hydragas pipe to clips on buttress.
27. Fit bolts securing resonator to body.
28. Lower LH engine mounting onto buttress and tighten bolt to 80 Nm.
29. Clean end of both drive shaft inboard joints and fit NEW circlips to shafts.
30. Lubricate differential oil seals.
31. Wipe taper joints of both hub ball joints and upper arms.
32. Fit both hub assemblies to upper arms and engage both drive shafts to differential.
33. Fit lock washers to upper ball joint pins and tighten nuts to 54 Nm.
34. Bend lock washers upward to lock nuts.

NOTE: Pull outwards on drive shaft inboard joints to check for full engagement.

35. Align both hubs to lower arms and tighten bolts to 100 Nm.
36. Wipe tapers and seats of track control arms and hubs.
37. Fit track control arms to hubs and tighten nuts to 30 Nm.
38. Fit bolts securing anti-roll bar to LH and RH links and tighten nuts to 35 Nm.
39. Fit calipers to hubs and tighten bolts to 85 Nm.
40. Clean ABS sensors, sensor spacers and mating faces on hubs.
41. Fit ABS spacers and sensors to hubs and tighten bolts to 10 Nm.
42. Secure ABS sensor cables to clips on upper suspension arms.
43. Fit LH ABS sensor cables to clips on subframe.
44. Fit clutch slave cylinder mounting bracket. Fit and tighten bolts.
45. Secure starter motor lead clip to clutch slave cylinder mounting bracket.
46. Up to 2000MY: Fit new ’O’ ring seal to speedometer cable pinion housing, fit pinion to gearbox and tighten bolt to 10 Nm.
47. 2000MY ON: Fit new ’O’ ring to road speed transducer, fit transducer to gearbox and tighten bolt to 12 Nm.
48. Connect multiplug to transducer.
49. All models: Fit clutch slave cylinder to bracket and secure pipe to clip on under side.
50. Tighten bolts securing slave cylinder to 25 Nm.
51. Clean clutch push rod, and clevis pin.
52. Grease clevis pin and end of push rod.
53. Fit push rod to cylinder, align rod to clutch lever and fit clevis pin.
54. Fit NEW ’R’ clip to secure clevis pin.
55. Connect reverse lamp switch wires.
56. Connect air intake hose to resonator and tighten clip.
57. Fit starter motor. See ELECTRICAL, Repairs.
58. Fit air cleaner duct to resonator.
59. Fit air cleaner mounting bracket. Fit and tighten bolts.
60. Fit fuel pipe clip to stud on body and tighten nut.
61. Fit hand brake and speedometer cables to clips on air cleaner bracket.
62. Fit fuel filter bracket to air cleaner bracket and tighten nuts.
63. Fit air cleaner. See ENGINE MANAGEMENT SYSTEM - MEMS, Repairs.
64. Fill gearbox with oil. See MAINTENANCE.
65. Connect battery earth lead.
66. Pressurise LH side of suspension. See FRONT SUSPENSION, Adjustments.