Trans
installation checklist
Replacing the shifter coupler? If so, do it now
Position transmission under the car, attach lifting chain to top of transmission lifting eye
Make sure intermediate axel and its housing are installed in bearing support
Remove all transmission mounting nuts from studs and bolts
Raise and engage transmission, install one nut
Make sure intermediate shaft is properly mated, then install all trans nuts and bolts
 | 19mm nut and bolt at the bottom front |
| 15mm bolt at bottom rear |
| 15mm bolt below the starter |
| 19mm nuts at the top front and center (leave one) |
| Torque large bolts/nuts to 60 ft-lbs |
Reconnect the tripod joint
Hang subframe on pivot bolts
Check spacer alignment at front suspension bracket mount point; pre-glue if necessary
Remove all nuts and bolts from the subframe and frame, rotate subframe up, position jack under it at front corner.
Jack it upward, aligning sway bar link
Lever trans mount into position; monitor it to keep it from binding
Engage ball joint stud
Install bolts
| Two 13 mm bolts at left front |
| Two 14 mm bolts/17 mm nuts at front near hinge bolt |
| 16 mm bolt to stay rod |
| Two 14 mm bolts/17 mm nuts at rear near hinge bolt |
| Two 13 mm bolts at suspension mount/front of suspension bracket |
| Two 14 mm bolts at rear of suspension bracket |
Install sway bar link nut
Install sway bar bushing bracket bolts (steering wheel full left)
Install ball joint pinch bolt
Torque subframe bolts to 40 ft-lbs. Torque ball joint clamp bolt to 20 ft-lbs, then install e-clip.
Tighten the subframe hinge bolts
Install transmission mount bolt, torque to 50 ft-lbs
Remove engine support
Reinstall shift coupler and speedo cable
Reinstall starter motor
Reconnect slave cylinder hose
Reconnect reverse light switch
Reconnect ground cable
Reconnect turbo delivery pipe
| Connection at throttle body |
| Connection at intercooler (from beneath the car) |
| Connection to the turbo bypass valve (smaller hose in the middle of the duct) |
| Temperature probe electrical connection |
Reinstall air cleaner and housing.
| Lettering on air cleaner housing faces up, locating tabs for AMM clips face fore and aft. |
Install AMM
Install battery holder
Reconnect cables to terminal block
Reinstall washer fluid reservoir and washer pump, refill reservoir
Reinstall battery, connect cables
Reinstall wheel liner and fender trim piece
Reinstall wheels, lower car , torque wheel nuts to 80 ft-lbs
Check top of the engine for loose components
| PCV stuff and vacuum grommets and hoses. |
Bleed clutch
Assemble tools, test drive