MANUAL TRANSAXLE REMOVAL/INSTALLATION [A26M-R (MZR-CD 2.2)]

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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.  Disconnect the negative battery cable. (See BATTERY REMOVAL/INSTALLATION [MZR-CD 2.2].)

2.  Remove the engine cover. (See ENGINE COVER REMOVAL/INSTALLATION [MZR-CD 2.2].)

3.  Drain the engine coolant. (See ENGINE COOLANT REPLACEMENT [MZR-CD 2.2].)

4.  Remove the following parts:

(1)  Air cleaner and air inlet hose (See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [MZR-CD 2.2].)

(2)  Battery and battery tray (See BATTERY REMOVAL/INSTALLATION [MZR-CD 2.2].)

(3)  Air inlet pipe and turbocharger air outlet pipe No.2 (See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [MZR-CD 2.2].)

(4)  EGR cooler and EGR cooler bypass valve component (See EGR COOLER REMOVAL/INSTALLATION [MZR-CD 2.2].)

(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.)

(8)  Front pipe bracket No.1 (See EXHAUST SYSTEM REMOVAL/INSTALLATION [MZR-CD 2.2].)

5.  Cut off the vacuum chamber installation bolt and set the vacuum chamber aside so that it does not interfere with the servicing.

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6.  Remove the front pipe bracket No.2. (See EXHAUST SYSTEM REMOVAL/INSTALLATION [MZR-CD 2.2].)

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

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

9.  Remove in the order indicated in the table.

10.  Install in the reverse order of removal.

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

12.  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 OVERHAUL' and verify that there is no abnormality. (See INSPECTION AFTER TRANSAXLE INSTALLATION [A26M-R].)

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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	Harness bracket
8	Clutch release cylinder
9	Starter (See STARTER REMOVAL/INSTALLATION [MZR-CD 2.2].)
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 [MZ-CD 1.6, MZR-CD 2.2].)
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.

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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 as shown in the figure.

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2.  Remove the bolt as shown in the figure.

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No.4 Engine Mount Removal Note

1.  Detach the hose clip as shown in the figure.

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

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3.  Install the SST using the following procedure.

Caution

•  Refer to the SST instruction manual for the basic handing procedure.

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(1)   As shown in the figure, set the rear shafts of the SST to the left and right shock absorber installation nut.

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(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.

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(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.

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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.

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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.

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

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4.  Support the transaxle on a jack.

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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.

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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.

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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 bolts in the order as shown in the figure.

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3.  Tighten the bolt as shown in the figure.

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

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5.  Tighten the bolts in the order as shown in the figure.

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6.  Tighten the nuts as shown in the figure.

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