MANUAL TRANSAXLE REMOVAL/INSTALLATION [F35M-R]

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Removal

1.  Disconnect the negative battery cable. (See NEGATIVE BATTERY CABLE DISCONNECTION/CONNECTION [MZR 1.6].)

2.  Remove the front under cover No.2. (See FRONT UNDER COVER No.2 REMOVAL/INSTALLATION.)

3.  Remove the front under cover No.1. (See FRONT UNDER COVER No.1 REMOVAL/INSTALLATION.)

4.  Remove the splash shield. (See SPLASH SHIELD REMOVAL/INSTALLATION.)

5.  Drain the manual transaxle oil. (See MANUAL TRANSAXLE OIL REPLACEMENT [F35M-R].)

6.  Disconnect and/or remove the following parts in the engine compartment.

(1)  Remove the air cleaner and air hose as a single unit. (See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [MZR 1.6].)

(2)  Remove the battery tray and PCM component. (See BATTERY REMOVAL/INSTALLATION [MZR 1.6].)

(3)  Disconnect the control cable from MTX. (See MANUAL TRANSAXLE SHIFT MECHANISM REMOVAL/INSTALLATION [F35M-R].)

(4)  Remove the control cable bracket from MTX.

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(5)  Remove the bolt shown in the figure, and set the ground cable aside.

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(6)  Disconnect the neutral switch connector from MTX. (See NEUTRAL SWITCH REMOVAL/INSTALLATION [F35M-R].)

(7)  Disconnect the back-up light switch connector from MTX. (See BACK-UP LIGHT SWITCH REMOVAL/INSTALLATION [F35M-R].)

(8)  Disconnect the wiring harness clips from the MTX, and set the wiring harness aside.

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7.  Disconnect and/or remove the following parts related to the suspension and axle.

(1)  Remove the front tires. (See WHEEL AND TIRE REMOVAL/INSTALLATION.)

(2)  Disconnect the clip securing the brake hose from the front shock absorber. (See BRAKE HOSE (FRONT) REMOVAL/INSTALLATION.)

(3)  Disconnect the front ABS wheel-speed sensors from the steering knuckles. (See FRONT ABS WHEEL-SPEED SENSOR REMOVAL/INSTALLATION.)

(4)  Disconnect the tie-rod end ball joints from the steering knuckles. (See FRONT CROSSMEMBER REMOVAL/INSTALLATION [MZR 1.6].)

(5)  Disconnect the front stabilizer control links from the front stabilizer. (See FRONT STABILIZER REMOVAL/INSTALLATION.)

(6)  Disconnect the front lower arms from the steering knuckles. (See FRONT LOWER ARM REMOVAL/INSTALLATION.)

(7)  Disconnect the front drive shaft (LH) from the MTX. (See FRONT DRIVE SHAFT REMOVAL/INSTALLATION.)

(8)  Disconnect the front drive shaft (RH) from the MTX. (See FRONT DRIVE SHAFT REMOVAL/INSTALLATION.)

8.  Disconnect and/or remove the following parts from the underside of the vehicle.

(1)  Remove the clutch release cylinder with the clutch pipe still connected and set it out of the way. (See CLUTCH RELEASE CYLINDER REMOVAL/INSTALLATION [F35M-R].)

(2)  Remove the starter. (See STARTER REMOVAL/INSTALLATION [MZR 1.6].)

(3)  Remove the front crossmember component and No.1 engine mount rubber as a single unit. (See FRONT CROSSMEMBER REMOVAL/INSTALLATION [MZR 1.6].)

(4)  Remove the bracket plate and No.1 engine mount bracket from the MTX.

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9.  Install the SST (49 C017 5A0, 49 UN30 3050, 49 L017 5A0) using the following procedure.

Caution

•  Refer to the SST (49 C017 5A0) instruction manual for the basic handing procedure.

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(1)  Install one front foot No.2 to each of the left and right front shafts of the SST (49 C017 5A0).

(2)  Protect the positions shown in the figure using tape.

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(3)  To enable to install the SST, disconnect the clip shown in the figure and set the wiring harness aside.

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(4)  Install the SST (49 UN30 3050) using part number 99794 1025 or an M10 × 1.25, length 25 mm {0.98 in} bolt as shown in the figure.

Engine front side

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Tightening torque

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

Engine rear side

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Tightening torque

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

(5)  As shown in the figure, set the rear shafts of the SST (49 C017 5A0) to the left and right front shock absorber nuts.

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(6)  As shown in the figure, set the front shafts of the SST (49 C017 5A0) to the left and right bolts.

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(7)  When assembling the SST (49 L017 5A0), disconnect the fuel hose from the clip shown in the figure to prevent interference between the fuel hose and SST.

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(8)  Install the SST (49 L017 5A0) to the SST (49 C017 5A0) as shown in the figure.

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(9)  Install the SST (49 L017 5A0) to the SST (49 UN30 3050) with the hook of the SST (49 L017 5A0) facing outward.

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(10)  Adjust the height of the left and right side bars so that they are leveled, then tighten each part of the SST (49 C017 5A0).

(11)  Apply tension to the chain to secure the engine.

10.  Remove in the order indicated in the table.

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1	Transaxle mounting bolt (upper side)
2	No.4 engine mount bracket (See No.4 Engine mount bracket removal note.)
3	No.4 engine mount support bracket
4	Transaxle mounting bolt (lower side) (See Transaxle mounting bolt removal note.)
5	MTX

No.4 Engine mount bracket removal note

Caution

•  A slot has been adopted for the No.4 engine mount bracket installation hole. If the No.4 engine mount bracket is deviated from the original position when installing the No.4 engine mount, engine noise or vibration could increase. When removing the No.4 engine mount, place alignment marks on the No.4 engine mount bracket so that they can be assembled to the same positions as before removal.

1.  Place alignment marks on the locations shown in the figure so that they can be assembled to the same positions as before removal.

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Note

•  Paint so that the outline of the nut is framed on the bracket side.

2.  Remove the No.4 engine mount bracket.

Transaxle mounting bolt removal note

Warning

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

1.  Adjust the SST (49 C017 5A0) and lean the engine toward the MTX.

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2.  Support the MTX on a jack.

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3.  Remove the transaxle mounting bolts (lower side).

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4.  Remove the MTX.

Installation

Warning

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

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

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2.  Install the MTX to the engine, and tighten the transaxle mounting bolts.

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3.  Tighten the stud bolts for the MTX.

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4.  Install the No.4 engine mount bracket to No.4 engine mount rubber, and temporarily tighten the installation bolt.

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5.  Tighten the No.4 engine mount support bracket installation nuts in the order shown in the figure.

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6.  Tighten the stud bolts for the No.4 engine mount support bracket.

7.  Lift up the MTX using the SSTs (49 C017 5A0, 49 L017 5A0), pass the No.4 engine mount support bracket stud bolts through the No.4 engine mount bracket, and temporarily tighten the No.4 engine mount installation nuts.

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8.  Install the No.1 engine mount bracket and bracket plate to the MTX, and temporarily tighten the installation bolts.

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9.  Install the front crossmember component and No.1 engine mount rubber as a single unit. (See FRONT CROSSMEMBER REMOVAL/INSTALLATION [MZR 1.6].)

10.  Temporarily tighten the No.1 engine mount rubber installation bolts.

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11.  Align the positions of the No.4 engine mount bracket installation nuts with the No.4 engine mount bracket.

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12.  Tighten the No.4 engine mount bracket installation nuts and bolt in the order shown in the figure.

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13.  Tighten the No.1 engine mount bracket and bracket plate installation bolts in the order shown in the figure.

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14.  Remove the SSTs (49 C017 5A0, 49 L017 5A0).

15.  Tighten the No.1 engine mount rubber installation bolts.

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16.  Connect and/or Install the following parts to the underside of the vehicle.

(1)  Install the starter. (See STARTER REMOVAL/INSTALLATION [MZR 1.6].)

(2)  Install the clutch release cylinder to the MTX. (See CLUTCH RELEASE CYLINDER REMOVAL/INSTALLATION [F35M-R].)

17.  Connect and/or Install the following parts related to the suspension and axle.

(1)  Connect the front drive shaft (RH) to the MTX. (See FRONT DRIVE SHAFT REMOVAL/INSTALLATION.)

(2)  Connect the front drive shaft (LH) to the MTX. (See FRONT DRIVE SHAFT REMOVAL/INSTALLATION.)

(3)  Connect the front lower arms to the steering knuckles. (See FRONT LOWER ARM REMOVAL/INSTALLATION.)

(4)  Connect the front stabilizer control links to the front stabilizer. (See FRONT STABILIZER REMOVAL/INSTALLATION.)

(5)  Connect the tie-rod end ball joints to the steering knuckles. (See FRONT CROSSMEMBER REMOVAL/INSTALLATION [MZR 1.6].)

(6)  Connect the front ABS wheel-speed sensors to the steering knuckles. (See FRONT ABS WHEEL-SPEED SENSOR REMOVAL/INSTALLATION.)

(7)  Connect the clip securing the brake hose to the front shock absorber. (See BRAKE HOSE (FRONT) REMOVAL/INSTALLATION.)

(8)  Install the front tires. (See WHEEL AND TIRE REMOVAL/INSTALLATION.)

18.  Connect and/or install the following parts in the engine compartment.

(1)  Connect the fuel hose to the clip shown in the figure.

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(2)  Connect the clip shown in the figure.

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(3)  Connect the wiring harness clips to the MTX.

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(4)  Connect the back-up light switch connector. (See BACK-UP LIGHT SWITCH REMOVAL/INSTALLATION [F35M-R].)

(5)  Connect the neutral switch connector. (See NEUTRAL SWITCH REMOVAL/INSTALLATION [F35M-R].)

(6)  Connect the ground cable to the No.4 engine mount bracket.

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(7)  Install the control cable bracket to the MTX.

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(8)  Connect the control cable to the MTX. (See MANUAL TRANSAXLE SHIFT MECHANISM REMOVAL/INSTALLATION [F35M-R].)

(9)  Install the battery tray and PCM component. (See BATTERY REMOVAL/INSTALLATION [MZR 1.6].)

(10)  Install the air cleaner and air hose as a single unit. (See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [MZR 1.6].)

19.  Install the splash shield. (See SPLASH SHIELD REMOVAL/INSTALLATION.)

20.  Install the front under cover No.1. (See FRONT UNDER COVER No.1 REMOVAL/INSTALLATION.)

21.  Add the specified amount of specified manual transaxle oil. (See MANUAL TRANSAXLE OIL REPLACEMENT [F35M-R].)

22.  Install the front under cover No.2. (See FRONT UNDER COVER No.2 REMOVAL/INSTALLATION.)

23.  Connect the negative battery cable. (See NEGATIVE BATTERY CABLE DISCONNECTION/CONNECTION [MZR 1.6].)

24.  If the MTX is overhauled, perform the “INSPECTION AFTER MANUAL TRANSAXLE OVERHAUL”. (See INSPECTION AFTER MANUAL TRANSAXLE OVERHAUL [F35M-R].)