MANUAL TRANSAXLE REMOVAL/INSTALLATION [B76M-R]

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1.  Disconnect the negative battery cable.

2.  Remove the aerodynamic under cover No.2 and the splash shield as a single unit. (See AERODYNAMIC UNDER COVER NO.2 REMOVAL/INSTALLATION.) (See SPLASH SHIELD REMOVAL/INSTALLATION.)

3.  Drain the manual transaxle oil. (See MANUAL TRANSAXLE OIL REPLACEMENT [B76M-R].)

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

(1)  Remove the air cleaner component. (ex: air cleaner, air hose) (See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [MZ-CD 1.6].)

(2)  Remove the battery component. (ex: battery, battery tray) (See BATTERY REMOVAL/INSTALLATION [MZ-CD 1.6].)

(3)  Disconnect the clutch pipe and hose No.2 from MTX and the clutch release cylinder, and plug it to avoid clutch fluid leakage. (See CLUTCH PIPE AND HOSE REMOVAL/INSTALLATION [B76M-R].)

(4)  Disconnect the control cable from MTX. (See MANUAL TRANSAXLE SHIFT MECHANISM REMOVAL/INSTALLATION.)

(5)  Disconnect the connectors and GND wiring harness from the MTX.

(6)  Remove the brackets from MTX.

(7)  Remove the catalyst converter front insulator installation bolts and set the exhaust manifold insulator aside. (SeeEXHAUST SYSTEM REMOVAL/INSTALLATION [MZ-CD 1.6].)

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

(1)  Remove the front tires. (See GENERAL PROCEDURES (FRONT AND REAR AXLES).)

(2)  Disconnect the clip securing the brake hose from the shock absorber. (See BRAKE HOSE (FRONT) REMOVAL/INSTALLATION [EXCEPT MZR 2.3 DISI Turbo].)

(3)  Disconnect the 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 1.5, MZR 1.6, MZR 2.0, MZR 2.3 DISI Turbo, MZR 2.5, MZ-CD 1.6].)

(5)  Disconnect the stabilizer control links (upper side) from the shock absorbers. (See FRONT STABILIZER REMOVAL/INSTALLATION [EXCEPT MZR 2.3 DISI Turbo].)

(6)  Disconnect the front lower arms from the steering knuckles. (See FRONT CROSSMEMBER REMOVAL/INSTALLATION [MZR 1.5, MZR 1.6, MZR 2.0, MZR 2.3 DISI Turbo, MZR 2.5, MZ-CD 1.6].)

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

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

(9)  Remove the joint shaft. (See JOINT SHAFT REMOVAL/INSTALLATION [MZ-CD 1.6, MZR-CD 2.2].)

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

(1)  Remove the hanger rubber as shown in the figure.

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(2)  Remove the starter. (See STARTER REMOVAL/INSTALLATION [MZ-CD 1.6].)

7.  Install the SST using the following procedure.

Caution

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

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(1)  Align the bolt of the shock absorber (RH) shown in the figure with the rear shaft hole for the right side of the SST.

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(2)  Align the bolt of the shock absorber (LH) shown in the figure with the rear shaft hole for the left side of the SST.

(3)  Install one front foot No.2 to each of the left and right front shafts of the SST, and then align the holes of the SST front shafts with the bolt on the left and right side of each front side frame.

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(4)  Set the SST as shown in the figure.

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(5)  Set the SST as shown in the figure.

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

(7)  Make sure each joint is securely tightened.

8.  Remove in the order indicated in the table.

9.  Install in the reverse order of removal.

10.  Add the specified amount of specified transaxle oil. (See MANUAL TRANSAXLE OIL REPLACEMENT [B76M-R].)

11.  Bleed the air from the clutch system. (See CLUTCH FLUID REPLACEMENT/AIR BLEEDING [B76M-R].)

12.  If the manual transaxle is overhauled, perform the “INSPECTION AFTER MANUAL TRANSAXLE OVERHAUL”. (See INSPECTION AFTER MANUAL TRANSAXLE OVERHAUL [B76M-R].)

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1	No.1 engine mount bracket (See No.1 Engine Mount and No.4 Engine Mount Installation Note.)
2	Transaxle mounting bolt (upper side)
3	Dynamic damper
4	Battery tray bracket
5	No.4 engine mount rubber (See No.1 Engine Mount and No.4 Engine Mount Installation Note.)
6	No.4 engine mount bracket (See No.4 Engine Mount Bracket Removal Note.) (See No.1 Engine Mount and No.4 Engine Mount Installation Note.)
7	Transaxle mounting bolt (lower side) (See Transaxle Mounting Bolt (Lower Side) Removal Note.)
8	Manual transaxle (See Manual Transaxle Installation Note.)

No.4 Engine Mount Bracket Removal Note

1.  Remove the No.4 engine mount bracket installation bolt (upper).

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2.  Tilt the engine and transaxle using the SST as shown in the figure.

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Note

•  Tilt the engine and transaxle to secure an operation space for removing the No.4 engine mount bracket installation bolts (side).

3.  Remove the No.4 engine mount bracket.

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Transaxle Mounting Bolt (Lower Side) 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 as shown in the figure.

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4.  Remove the transaxle mounting bolts as shown in the figure.

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

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

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5.  Remove the transaxle from the vehicle.

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.

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

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

1.  Install the No.4 engine mount bracket to the transaxle case.

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2.  Install the No.1 engine mount bracket to the transaxle case.

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3.  Temporarily tighten the bolts as shown in the figure.

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4.  Place the No.4 engine mount rubber with the body stud bolts passing through the holes and tighten the bolt in the figure.

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5.  Fully tighten the bolts in the order shown in the figure.

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6.  Place the battery bracket on the No.4 Engine mount rubber with the body stud bolts passing through the holes and tighten bolts and nuts in the order shown in the figure.

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7.  Remove the SST (49 C017 5A0).