MANUAL TRANSAXLE REMOVAL/INSTALLATION [G66M-R]

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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 1.8, MZR 2.0, MZR 2.5].)(See BATTERY REMOVAL/INSTALLATION [MZR 2.0 DISI].)

2.  Remove the following parts:

(1)  Battery and battery tray (MZR 2.0, MZR 2.5)(See BATTERY REMOVAL/INSTALLATION [MZR 1.8, MZR 2.0, MZR 2.5].)

(2)  Battery component (ex: battery, battery tray and PCM component)(MZR 2.0 DISI)(See BATTERY REMOVAL/INSTALLATION [MZR 2.0 DISI].)

(3)  Air cleaner component (See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [MZR 1.8, MZR 2.0, MZR 2.5].)(See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [MZR 2.0 DISI].)

(4)  Front tires (See GENERAL PROCEDURES (SUSPENSION).)

(5)  Splash shields (See SPLASH SHIELD REMOVAL/INSTALLATION.)

(6)  Plug hole plate (See PLUG HOLE PLATE REMOVAL/INSTALLATION [MZR 1.8, MZR 2.0, MZR 2.5].)(See PLUG HOLE PLATE REMOVAL/INSTALLATION [MZR 2.0 DISI].)

(7)  Aerodynamic under cover No.2 (See AERODYNAMIC UNDER COVER NO.2 REMOVAL/INSTALLATION.)

(8)  Aerodynamic under cover No.1 (See AERODYNAMIC UNDER COVER NO.1 REMOVAL/INSTALLATION.)

(9)  Tunnel member (See EXHAUST SYSTEM REMOVAL/INSTALLATION [MZR 1.8, MZR 2.0, MZR 2.5].)(See EXHAUST SYSTEM REMOVAL/INSTALLATION [MZR 2.0 DISI].)

(10)  Floor under cover (left side)(See FLOOR UNDER COVER REMOVAL/INSTALLATION.)

3.  Disconnect the A/F sensor connector. (See AIR FUEL RATIO (A/F) SENSOR REMOVAL/INSTALLATION [MZR 1.8, MZR 2.0, MZR 2.5].)(See AIR FUEL RATIO (A/F) SENSOR REMOVAL/INSTALLATION [MZR 2.0 DISI].)

4.  Disconnect the HO2S connector. (See HEATED OXYGEN SENSOR (HO2S) REMOVAL/INSTALLATION [MZR 1.8, MZR 2.0, MZR 2.5].)(See HEATED OXYGEN SENSOR (HO2S) REMOVAL/INSTALLATION [MZR 2.0 DISI].)

5.  Remove the hanger on the TWC side as shown in the figure and set the hanger aside.

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6.  Remove the steering shaft cover. (See STEERING GEAR AND LINKAGE REMOVAL/INSTALLATION [L.H.D.].)(See STEERING GEAR AND LINKAGE REMOVAL/INSTALLATION [R.H.D.].)

7.  Remove the joint bolt for the steering shaft and disconnect the steering shaft from the steering gear and linkage side. (See STEERING GEAR AND LINKAGE REMOVAL/INSTALLATION [L.H.D.].)(See STEERING GEAR AND LINKAGE REMOVAL/INSTALLATION [R.H.D.].)

8.  Drain the transaxle oil into a suitable container. (See TRANSAXLE OIL REPLACEMENT [G66M-R].)

Warning

•  Improperly jacking a transaxle is dangerous. It can slip off the jack and may cause serious injury.

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 [G66M-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 [G66M-R].)

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1	GND wiring harness
2	Back-up light switch connector
3	Neutral switch connector
4	Harness bracket
5	Selector cable (See Shift Cable and Selector Cable Removal Note.)
6	Shift cable (See Shift Cable and Selector Cable Removal Note.)
7	Cable bracket
8	Clutch release cylinder bracket
9	Clutch release cylinder (See CLUTCH RELEASE CYLINDER REMOVAL/INSTALLATION [G66M-R].)
10	Heater hose bracket
11	Starter (See STARTER REMOVAL/INSTALLATION [MZR 1.8, MZR 2.0, MZR 2.5].) (See STARTER REMOVAL/INSTALLATION [MZR 2.0 DISI].)
12	Transaxle mounting bolt (upper side)
13	Damper fork
14	Stabilizer control link
15	Tie-rod end ball joint (See FRONT CROSSMEMBER REMOVAL/INSTALLATION.)
16	Lower arm ball joint
17	No.1 engine mount (See No.1 Engine Mount and No.4 Engine Mount Installation Note.)
18	Crossmember bracket
19	Crossmember component (See FRONT CROSSMEMBER REMOVAL/INSTALLATION.)
20	Drive shaft (LH) (See DRIVE SHAFT REMOVAL/INSTALLATION.)
21	Drive shaft (RH) (See DRIVE SHAFT REMOVAL/INSTALLATION.)
22	Joint shaft (See JOINT SHAFT REMOVAL/INSTALLATION.)
23	GND wiring harness
24	No.4 engine mount bracket (See No.4 Engine Mount Removal Note.) (See No.1 Engine Mount and No.4 Engine Mount Installation Note.)
25	Transaxle mounting bolt (lower side)
26	Manual transaxle (See Manual Transaxle Removal Note.) (See Manual Transaxle Installation Note.)

Shift Cable and Selector Cable Removal Note

1.  Remove the both shift cable end and selector cable end using a fastener remover.

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No.4 Engine Mount Removal Note

1.  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.

2.  Support the engine using the SST.

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3.  Remove the 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.  Remove the bolt securing the brake hose to the bracket as shown in the figure, and disconnect brake hose from the bracket.

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3.  Support the transaxle on a jack.

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4.  Remove the transaxle mounting bolts.

5.  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 and tighten the bolt shown in the figure.

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

1.  Install the No.1 engine mount bracket to the No.1 engine mount rubber as shown in the figure.

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2.  Temporarily tighten the bolt G.

3.  Install the No.1 engine mount bracket to the transaxle and temporarily tighten bolts A and B.

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4.  Tighten the bolts in the order of A and B.

5.  Align the stud bolts to their installation holes and install the No.4 engine mount bracket to the transaxle.

6.  Align the No.4 engine mount bracket installation hole to the No.4 engine mount rubber on the body and temporarily tighten bolt C.

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7.  Temporarily tighten bolt D, and then the nuts in the order of E and F.

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8.  Tighten bolt D, and then the nuts in the order of E and F.

9.  Tighten the bolt C.

10.  Tighten the bolt G.

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11.  Tighten the bolt H.

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