Transaxle Installation
Transaxle
Special Tool(s)
General Equipment
Installation
NOTE: Only use new self-locking nuts.
1. Raise and support the vehicle.
2. CAUTION: Make sure that the two locating dowels are installed.
Using a retaining strap and wooden blocks, secure the transaxle on a transmission jack.
3. Install the transaxle. Make sure the transaxle is flush to the engine.
4. Install the two bolts at the dowels first. Torque to specification.
^ Failure to follow these steps will result in gear rattle at idle.
5. Install the remaining transaxle right-hand flange bolts.
6. Push the engine forward and install an approximately 350 mm long wooden block between the engine and the crossmember.
^ Move the transaxle into position.
7. Install the transaxle lower flange bolts.
8. Remove the retaining strap from the transaxle.
9. Remove the wooden block.
10. Remove the transmission jack.
11. Connect the Vehicle Speed Sensor (VSS) electrical connector.
12. Attach the starter motor to the transaxle.
13. Lower the vehicle.
14. Install the two transaxle upper flange bolts.
15. Install the engine rear mount bracket.
16. Using the special tools, raise the engine and transaxle assembly slightly.
17. Install the engine rear mount.
18. Remove the special tools (illustration shows battery installed)
19. Connect the reversing lamp switch electrical connector.
20. WARNING: Escaping brake fluid. Do not allow brake fluid to come into contact with the skin or the eyes. If brake fluid does come into contact with the skin or the eyes, rinse the affected areas with water immediately. Failure to follow these instructions may result in personal injury.
CAUTION: If brake fluid is spilt on the paintwork, the affected area must be immediately washed down with cold water.
Connect the clutch slave cylinder supply line.
^ Insert the clip.
21. NOTE: The shift cable abutment sleeve is colored white.
NOTE: The selector cable abutment sleeve is colored black.
Attach the transaxle cables to the bracket.
1 Attach the shifter cable to the bracket, turning the abutment sleeves counterclockwise to open. Position the cables into the metal holders.
2 Attach the selector cable to the bracket, turning the abutment sleeves counterclockwise to open. Position the cables into the metal holders.
22. Attach the gearshift cables.
1 Attach the shifter cable to the shift mass.
2 Attach the selector cable to the selector lever.
23. Check the shill cables at the metal holders. Pull outward on the cables. Cables should remain in the metal holders.
24. Adjust the shift cables.
25. Raise and support the vehicle.
26. Install the drive belt cover.
27. CAUTION: Support the halfshaft inner joint must not be bent more than 18 degrees. The outer joint must not be bent more than 45 degrees.
CAUTION: Do not damage the halfshaft seal.
Attach the halfshaft together with the intermediate shaft to the transaxle.
28. CAUTION: Support the halfshaft. The inner joint must not be bent more than 18 degrees. The outer joint must not be bent more than 45 degrees.
NOTE: Install a new center bearing cap and locknuts.
Install the intermediate shaft center bearing cap.
29. CAUTION: Support the halfshaft. The inner joint must not be bent more than 18 degrees. The outer joint must not be bent more than 45 degrees.
CAUTION: Do not damage the halfshaft seal.
CAUTION: Make sure the snap ring is correctly seated.
NOTE: Install a new snap ring.
Attach the left-hand halfshaft to the transaxle.
30. Install the lower arm ball joints on both sides.
^ Install the heat shield.
31. Install the engine roll restrictor.
32. Install the flexible exhaust pipe.
33. Install the front wheels and tires.
34. Lower the vehicle.
35. NOTE: The resonator is a push fit into the bracket.
Install the air cleaner intake and resonator.
36. Install the intake tube.
37. Connect the ground cable.
38. Install the air cleaner housing.
1 Connect the intake hose.
2 Install the crankcase ventilation hose.
3 Install the Mass Air Flow Sensor (MAF sensor) connector.
39. Tighten the strut and spring assembly top mount nuts by five turns on troth sides.
40. Install the battery tray.
1 Attach the wiring harness.
2 Tighten the bolts.
3 Fasten the connector and clip it in.
41. Install the battery.
42. Adjust the gearshift cables.
43. Bleed the hydraulic clutch system.
44. Fill up the transaxle with manual transmission fluid.
45. NOTE: When the battery has been disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 miles) or more to relearn the strategy.
Finishing operations:
^ Connect the battery ground cable.
^ Carry out a road test to enable the Powertrain Control Module (PCM) to collect data.
^ Check the routing of the vacuum hoses and wiring and secure them with cable ties.
^ Check the engine and cooling system for leaks (visual inspection).