MANUAL TRANSAXLE REMOVAL/INSTALLATION [F35M-R]

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1.  Remove the battery cover. (See BATTERY REMOVAL/INSTALLATION [ZY, Z6].)

2.  Disconnect the negative battery cable. (See BATTERY REMOVAL/INSTALLATION [ZY, Z6].)

3.  Remove the following parts:

(1)  Battery and battery tray (See BATTERY REMOVAL/INSTALLATION [ZY, Z6].)
(2)  Fresh-air duct and the air cleaner as a single unit (See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [ZY, Z6].)
(3)  Front tires (See GENERAL PROCEDURES (SUSPENSION).)
(4)  Splash shield (See SPLASH SHIELD REMOVAL/INSTALLATION.)
(5)  Aerodynamic under cover No.2 (See AERODYNAMIC UNDER COVER NO.2 REMOVAL/INSTALLATION.)
(6)  EGR pipe (intake manifold side)(European (L.H.D. U.K.) specs.) (See EGR PIPE REMOVAL/INSTALLATION [ZY, Z6].)

4.  Drain the transaxle oil into a suitable container. (See TRANSAXLE OIL REPLACEMENT [F35M-R].)

5.  Remove in the order indicated in the table.

6.  Install in the reverse order of removal.

7.  Add the specified amount of specified transaxle oil. (See TRANSAXLE OIL REPLACEMENT [F35M-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 [F35M-R].)
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1
Neutral switch connector
2
Back-up light switch connector
3
Ground
4
Shift cable
(See Shift Cable and Select Cable Removal Note.)
5
Select cable
(See Shift Cable and Select Cable Removal Note.)
6
Cable bracket
7
Clutch release cylinder
(See CLUTCH RELEASE CYLINDER REMOVAL/INSTALLATION [F35M-R].)
8
Ground
9
Wiring harness bracket
10
Starter
(See STARTER REMOVAL/INSTALLATION [ZY, Z6].)
11
Transaxle mounting bolt (upper side)
12
Stabilizer control link
13
Tie-rod end ball joint
(See FRONT CROSSMEMBER REMOVAL/INSTALLATION [ZY, Z6, LF, L3 Turbo, L5, MZ-CD 1.6 (Y6)].)
14
Lower arm ball joint
15
Drive shaft (LH)
(See DRIVE SHAFT REMOVAL/INSTALLATION.)
16
Drive shaft (RH)
(See DRIVE SHAFT REMOVAL/INSTALLATION.)
17
Joint shaft
(See JOINT SHAFT REMOVAL/INSTALLATION [ZY, Z6, L3 Turbo, L5].)
18
No.1 engine mount bracket
(See No.1 Engine Mount Rubber Removal Note.)
(See No.1 Engine Mount and No.4 Engine Mount Installation Note.)
19
Battery tray bracket
20
No.4 engine mount rubber
(See No.4 Engine Mount Removal Note.)
(See No.1 Engine Mount and No.4 Engine Mount Installation Note.)
21
No.4 engine mount bracket
(See No.4 Engine Mount Removal Note.)
(See No.1 Engine Mount and No.4 Engine Mount Installation Note.)
22
Transaxle mounting bolt (lower side)
23
Manual transaxle
(See Manual Transaxle Removal Note.)
(See Manual Transaxle Installation Note.)


Shift Cable and Select Cable Removal Note

1.  Remove the shift and selector cable outer ends as shown in the figure.

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

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No.1 Engine Mount Rubber Removal Note

1.  Loosen the bolt shown in the figure.

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2.  Remove the bolt shown in the figure.

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No.4 Engine Mount Removal Note

1.  Detach the hose clip shown in the figure.

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2.  Remove the bracket bolt shown in the figure and set the bracket aside to prevent interference with the SST.

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3.  Remove the brake vacuum hose bracket bolt, then set the brake vacuum hose out of the way.

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4.  Set the fuel pipe bracket out of the way to prevent interference with the SST as shown in the figure.

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5.  Using the bolts part number 99794 1025 or M10×1.25, length 25 mm {0.98 in} to install the SST (49 UN30 3050) to the position shown in the figure.

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Tightening torque
38—51 N·m {3.9—5.2 kgf·m, 29—37 ft·lbf}

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

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

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

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

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

11.  Remove the No.4 engine mount.


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.

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2.  Support the transaxle on a jack.

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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.

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

Tightening torque
A: 64—89 N·m {6.6—9.0 kgf·m, 48—65 ft·lbf}
B: 38—52 N·m {3.9—5.3 kgf·m, 29—38 ft·lbf}


No.1 Engine Mount and No.4 Engine Mount Installation Note

1.  Install the No.4 engine mount bracket.

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Tightening torque
61—76 N·m {6.3—7.7 kgf·m, 45—56 ft·lbf}

2.  Tighten the No.4 engine mount rubber installation bolt.

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Tightening torque
94—152 N·m {9.6—15 kgf·m, 70—112 ft·lbf}

3.  Tighten the No.1 engine mount rubber installation bolts in the order shown.

Caution
•  Tighten the bolts in the order shown in the figure to prevent abnormal noise and vibration after assembly.
•  Tighten the bolts while being careful of their length to prevent interference between the steering gear housing and bolt.
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Bolt stem length
Front crossmember side: 62mm {2.4 in}
No.1 engine mount bracket side: 65mm {2.6 in}
Tightening torque
73—90 N·m {7.5—9.1 kgf·m, 54—66 ft·lbf}

4.  Tighten the No.4 engine mount rubber and battery tray bracket installation nuts as shown in the figure.

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Tightening torque
44—61 N·m {4.5—6.2 kgf·m, 33—44 ft·lbf}