MANUAL TRANSAXLE REMOVAL/INSTALLATION [A26M-R (L3 Turbo)]

id0515l18006l3

Caution
•  Secure the steering wheel using tape or a cable to prevent the steering shaft from rotating after disconnecting the steering shaft. If the steering wheel rotates after the steering shaft and the steering gear and linkage are disconnected, the internal parts of the clock spring could be damaged.

1.  Remove the battery cover. (See BATTERY REMOVAL/INSTALLATION [L3 Turbo].)

2.  Disconnect the negative battery cable. (See BATTERY REMOVAL/INSTALLATION [L3 Turbo].)

3.  Drain the engine coolant. (See ENGINE COOLANT REPLACEMENT [L3 Turbo].)

4.  Remove the PCM cover No.1. (See PCM REMOVAL/INSTALLATION [L3 Turbo].)

5.  Disconnect the PCM connector. (See PCM REMOVAL/INSTALLATION [L3 Turbo].)

6.  Remove the following parts:

(1)  Battery tray and PCM component (See BATTERY REMOVAL/INSTALLATION [L3 Turbo].)
(2)  Air cleaner component (See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [L3 Turbo].)
(3)  Charge air cooler cover (See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [L3 Turbo].)
(4)  Charge air cooler (See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [L3 Turbo].)
(5)  Front tires (See GENERAL PROCEDURES (SUSPENSION).)
(6)  Splash shield (See SPLASH SHIELD REMOVAL/INSTALLATION.)
(7)  Aerodynamic under cover No.2 (See AERODYNAMIC UNDER COVER NO.2 REMOVAL/INSTALLATION.)

7.  Remove the starter. (See STARTER REMOVAL/INSTALLATION [L3 Turbo].)

8.  Remove the front auto leveling sensor. (See AUTO LEVELING SENSOR REMOVAL/INSTALLATION.)

9.  Drain the transaxle oil into a suitable container. (See TRANSAXLE OIL REPLACEMENT [A26M-R].)

10.  Remove in the order indicated in the table.

11.  Install in the reverse order of removal.

12.  Perform the auto leveling system initialization. (See AUTO LEVELING SYSTEM INITIALIZATION.)

13.  Add the specified amount of specified transaxle oil. (See TRANSAXLE OIL REPLACEMENT [A26M-R].)

14.  Warm up the engine and transaxle, inspect for oil leakage, and inspect the transaxle operation.

Warning
•  Improperly jacking a transaxle is dangerous. It can slip off the jack and may cause serious injury.
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 [A26M-R].)
am3zzw00008406

1
Neutral switch connector
2
Back-up light switch connector
3
Selector cable
(See Shift Cable and Select Cable Removal Note.)
4
Shift cable
(See Shift Cable and Select Cable Removal Note.)
5
Cable rubber bracket
6
GND wiring harness
7
Clutch release cylinder
8
GND wiring harness
9
Wiring harness bracket
10
Transaxle mounting bolt (upper side)
11
Tie-rod end ball joint
(See FRONT CROSSMEMBER REMOVAL/INSTALLATION [MZR-CD 2.2].)
12
Stabilizer control link
13
Lower arm ball joint
14
No.1 engine mount
(See No.1 Engine Mount Rubber Removal Note.)
(See No.1 Engine Mount and No.4 Engine Mount Installation Note.)
15
Crossmember bracket
16
Crossmember component
(See FRONT CROSSMEMBER REMOVAL/INSTALLATION [MZR-CD 2.2].)
17
Drive shaft (LH)
(See DRIVE SHAFT REMOVAL/INSTALLATION)
18
Drive shaft (RH)
(See DRIVE SHAFT REMOVAL/INSTALLATION.)
19
Joint shaft
(See JOINT SHAFT REMOVAL/INSTALLATION [ZY, Z6, L3 Turbo, L5].)
20
Battery tray bracket
21
Cable bracket
22
No.4 engine mount rubber
(See No.4 Engine Mount Removal Note.)
(See No.1 Engine Mount and No.4 Engine Mount Installation Note.)
23
No.4 engine mount bracket
(See No.4 Engine Mount Removal Note.)
(See No.1 Engine Mount and No.4 Engine Mount Installation Note.)
24
Transaxle mounting bolt (lower side)
25
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 using a pliers.

am3uuw00002130

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

am6zzw00003261


No.1 Engine Mount Rubber Removal Note

1.  Loosen the No.1 engine mount rubber installation bolt (front crossmember side) as shown in the figure.

am3zzw00008291

2.  Remove the No.1 engine mount rubber installation bolt (No.1 engine mount bracket side) as shown in the figure.

am3zzw00008292

3.  Remove the No.1 engine mount rubber and the front crossmember component as a single unit.


No.4 Engine Mount Removal Note

1.  Detach the hose clip shown in the figure.

am3zzw00005457

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

am3zzw00005458

3.  Install the SST using the following procedure.

Caution
•  Refer to the SST instruction manual for the basic handing procedure.
am2zzw00000191
(1)   As shown in the figure, set the rear shafts of the SST to the left and right shock absorber installation nut.
am3zzw00008471
(2)  Install front foot No.2 to the left/right front shaft of the SST, then align the groove of the front shaft of the SST with the folded up part of the vehicle as shown in the figure.
am3zzw00008407
(3)  Adjust the positions of the SST side bars so that they are the same height (left and right) and horizontal.
(4)  Make sure each joint is securely tightened.

4.  Support the engine using the SST.

am3zzw00008408

5.  Remove the battery tray bracket, No.4 engine mount rubber and bracket.


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.

am3zzw00008408

2.  To prevent interference when removing the transaxle, remove the brake pipe from the clip as shown in the figure and set it in a place out of the way.

am3zzw00005462

3.  Remove the clip and suspend the brake hose as shown in the figure using a cable or similar item.

am3zzw00006012

4.  Support the transaxle on a jack.

am6zzw00003265

5.  Remove the transaxle mounting bolts.

6.  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.

am6zzw00003266

2.  Install the transaxle mounting bolts.

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

4.  Install the brake hose to the bracket as shown in the figure and install the clip.

am3zzw00006013


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

1.  Install the front crossmember component. (See FRONT CROSSMEMBER REMOVAL/INSTALLATION [MZR-CD 2.2].)

2.  Temporarily tighten the No.1 engine mount rubber installation bolt.

am3zzw00008292

3.  Tighten the bolt shown in the figure.

am3zzw00008293

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

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

am3uuw00003040

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

5.  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.
Bolt stem length
Front crossmember side: 62 mm {2.4 in}
No.1 engine mount bracket side: 65 mm {2.6 in}
am3zzw00008737
Tightening torque
73—90 N·m {7.5—9.1 kgf·m, 54—66 ft·lbf}

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

am3zzw00008294

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