MANUAL TRANSAXLE REMOVAL/INSTALLATION [B65M-R]

id0515h3800600

1.  Disconnect the negative battery cable. (See BATTERY REMOVAL/INSTALLATION [MZ-CD 1.6].)

2.  Remove the engine cover. (See BATTERY REMOVAL/INSTALLATION [MZ-CD 1.6].)

3.  Remove the battery and battery tray. (See BATTERY REMOVAL/INSTALLATION [MZ-CD 1.6].)

4.  Remove the front wheels and tires. (See GENERAL PROCEDURES (FRONT AND REAR AXLES).)

5.  Remove air hose and air cleaner component. (See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [MZ-CD 1.6].)

6.  Remove the hanger rubber from the exhaust pipe shown in the figure to remove the transaxle installation bolts.

am2zzw00003881

7.  Remove in the order indicated in the table.

8.  Install in the reverse order of removal.

9.  Add the specified amount of specified transaxle oil. (See TRANSAXLE OIL INSPECTION [B65M-R].)

Note

•  If the transaxle is overhauled and installed to the vehicle, perform the "INSPECTION AFTER TRANSAXLE INSTALLATION" and verify that there is no abnormality. (See INSPECTION AFTER TRANSAXLE INSTALLATION [B65M-R].)

am2zzw00005649

1	Battery tray bracket
2	Back-up light switch connector
3	Clutch pipe (See Clutch Pipe Removal Note.) (See Clutch Pipe Installation Note.)
4	Clutch pipe bracket
5	Cable bracket
6	Cable box cover
7	Shift cable (See Shift Cable and Select Cable Removal Note.)
8	Select cable (See Shift Cable and Select Cable Removal Note.)
9	Cable box
10	Starter (See STARTER REMOVAL/INSTALLATION [MZ-CD 1.6].)
11	Transaxle mounting bolt (upper side)
12	Nut (stabilizer control link upper side)
13	Bolt (brake hose bracket)
14	Tie-rod end ball joint (See FRONT CROSSMEMBER REMOVAL/INSTALLATION.)
15	ABS wheel-speed sensor (See ABS Wheel-Speed Sensor Removal Note.) (See ABS Wheel-Speed Sensor Installation Note.)
16	Front lower arm ball joint (See WHEEL HUB, STEERING KNUCKLE REMOVAL/INSTALLATION.)
17	Drive shaft (LH) (See DRIVE SHAFT REMOVAL/INSTALLATION [MZ-CD 1.6].)
18	Drive shaft (RH) (See DRIVE SHAFT REMOVAL/INSTALLATION [MZ-CD 1.6].)
19	Joint shaft (See JOINT SHAFT REMOVAL/INSTALLATION [MZ-CD 1.6].)
20	No.1 engine mount (See No.1 Engine Mount Rubber Installation Note.)
21	No.4 engine mount rubber (SeeNo.4 Engine Mount Rubber Removal Note.) (See No.4 Engine Mount Rubber Installation Note.)
22	No.4 engine mount bracket
23	Transaxle mounting bolt (lower side) (See Transaxle Mounting Bolt (lower side) Removal Note.)
24	Manual transaxle (See Manual Transaxle Removal Note.) (See Manual Transaxle Installation Note.)

Clutch Pipe Removal Note

Caution

•  When disconnecting the clutch pipe, the seal ring installed to the end of the clutch pipe may fall off or remain on the clutch release cylinder side. If the clutch pipe is assembled with the seal ring not installed, it may cause fluid leakage from the clutch pipe connector or the clutch may not operate normally. When disconnecting the clutch pipe, remove the seal ring and clutch pipe as a single unit.

1.  Remove the clip from the clutch release cylinder.

am2zzw00002944

2.  Remove the clutch pipe connector straight.

3.  Verify that the seal ring is removed together with the clutch pipe.

am2zzw00003993

Shift Cable and Select Cable Removal Note

1.  Remove the both shift cable end and select cable end using a fastener remover.

am2zzw00004095

2.  Remove the shift and select cable in the order shown in the figure.

am2zzw00004096

ABS Wheel-Speed Sensor Removal Note

1.  Remove the ABS wheel-speed sensor installation bolt, then remove the ABS wheel-speed sensor from the steering knuckle.

2.  Remove the bolts and nuts shown in the figure, then disconnect the steering knuckle from the shock absorber.

am2zzw00004097

3.  While pressing the tabs (2 locations) of the ABS wheel-speed sensor wiring harness clip, remove the ABS wheel-speed sensor wiring harness from the shock absorber.

am2zzw00004098

4.  Remove the ABS wheel-speed sensor wiring harness grommet from the shock absorber.

5.  Move the ABS wheel-speed sensor to a place out of the way.

6.  Install the steering knuckle to the shock absorber, insert the bolts from the direction shown as follows, then tighten them to the specified torque.

am2zzw00004099

―  Vehicle left side: Insert the bolts from the vehicle rear.

―  Vehicle right side: Insert the bolts from the vehicle front.

No.4 Engine Mount Rubber Removal Note

1.  Install front foot No.2 to the left/right front shaft of the SST (49 C017 5A0).

am2zzw00003101

2.  As shown in the figure, set the rear shafts of the SST to the left and right shock absorber upper bolts.

L.H.D.

am2zzw00005917

R.H.D.

am2zzw00005708

3.  Remove the coolant reserve tank from the clip and set it out of the way.

4.  Remove the cooler pipe from the clips and set it out of the way to prevent interference between the SST and the front shaft.

am2zzw00005651

5.  As shown in the figure, set the front shaft groove of the SST to the folded part of the left and right body frames.

am2zzw00005652

Caution

•  Block the removed area using a clean rag so that foreign material or water does not penetrate.

6.  Remove the oil filler cap.

7.  Set the SST as shown in the figure.

am2zzw00003864

8.  Hang the engine using the SST.

am2zzw00005653

9.  Adjust the height of the left and right side bars so that they are leveled, then tighten each part of the SST.

am2zzw00003086

10.  Verify that the SST is properly set and the engine is securely hung.

11.  Remove the No.4 engine mount.

Transaxle Mounting Bolt (lower side) Removal Note

1.  Loosen the transaxle installation bolt until it contacts the catalytic converter bracket.

am2zzw00003886

2.  While pulling the transaxle out in the direction of removal, remove the transaxle installation bolt from the transaxle.

am2zzw00003888

3.  Remove the transaxle from the vehicle.

Manual Transaxle Removal Note

Warning

•  Remove the transaxle carefully, holding it steady. If the transaxle falls it could be damaged or cause injury.

1.  Adjust the SST and lean the engine toward the transaxle.

am2zzw00003086

2.  Support the transaxle on a jack.

am3uuw00002584

3.  Remove the transaxle mounting bolts.

4.  Remove the transaxle.

Manual Transaxle Installation Note

Warning

•  Install the transaxle carefully, holding it steady. If the transaxle falls it could be damaged or cause injury.

1.  Set the transaxle on a jack and lift into place.

2.  Install the transaxle mounting bolts.

am2zzw00005918

3.  Adjust the SST (49 C017 5A0) so that the engine is located at the specified position.

No.4 Engine Mount Rubber Installation Note

1.  Tighten the nuts and bolts in the order of A to B.

am2zzw00005944

No.1 Engine Mount Rubber Installation Note

Caution

•  Align the transaxle bolt holes and the engine mount exactly. Any misalignment can result in bolts and bolt holes becoming damaged or stripped during installation.

1.  Adjust the SST (engine support), and align the hole of the No.1 engine mount with the bolt hole of transaxle.

2.  Tighten the bolt A, B.

am2zzw00002946

3.  Tighten the bolt C.

ABS Wheel-Speed Sensor Installation Note

1.  Install the ABS wheel-speed sensor wiring harness grommet to the shock absorber as shown in the figure.

am2zzw00004100

2.  Install the ABS wheel-speed sensor wiring harness clip to the shock absorber.

3.  Install the ABS wheel-speed sensor to the steering knuckle, then tighten the bolt (ABS wheel-speed sensor) to the specified torque.

4.  Verify that the ABS wheel-speed sensor wiring harness is not twisted.

Clutch Pipe Installation Note

Caution

•  When disconnecting the clutch pipe, the seal ring installed to the end of the clutch pipe connector may fall off or remain on the clutch pedal component clutch master cylinder side. If the clutch pipe is assembled with the seal ring not installed, it may cause fluid leakage from the clutch pipe connector or the clutch may not operate normally. When disconnecting the clutch pipe, remove the seal ring and clutch pipe connector as a single unit.

1.  Verify that the seal ring is installed to the groove at the end of the clutch pipe.

am2zzw00003991

2.  Install the clip from the clutch release cylinder.

am2zzw00002947

3.  Insert the clutch pipe connector straight.

4.  Pull the clutch pipe to verify that it does not come off, and reinsert it completely.