MANUAL TRANSAXLE REMOVAL/INSTALLATION [A26M-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-CD 2.2].)

2.  Remove the following parts:

(1)  Engine cover (See ENGINE COVER REMOVAL/INSTALLATION [MZR-CD 2.2].)

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

(3)  Air inlet hose No.1 and Air inlet hose No.2 (See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [MZR-CD 2.2].)

(4)  Air cleaner component (See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [MZR-CD 2.2].)

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

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

4.  Disconnect the vacuum hose. (See EGR COOLER REMOVAL/INSTALLATION [MZR-CD 2.2].)

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

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6.  Remove the front tires. (See GENERAL PROCEDURES (SUSPENSION).)

7.  Remove the splash shields. (See SPLASH SHIELD REMOVAL/INSTALLATION.)

8.  Remove the aerodynamic under cover No.2. (See AERODYNAMIC UNDER COVER NO.2 REMOVAL/INSTALLATION.)

9.  Remove the aerodynamic under cover No.1. (See AERODYNAMIC UNDER COVER NO.1 REMOVAL/INSTALLATION.)

10.  Remove the transverse member. (See TRANSVERSE MEMBER REMOVAL/INSTALLATION.)

11.  Remove the hanger on the oxidation catalytic converter (built-in diesel particulate filter) side and set the hanger aside.

12.  Remove the vacuum chamber installation nuts and set the vacuum chamber aside so that it is out of the way. (See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [MZR-CD 2.2].)

13.  Remove the joint pipe bracket. (See EXHAUST SYSTEM REMOVAL/INSTALLATION [MZR-CD 2.2].)

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

15.  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.].)

16.  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.].)

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

Warning

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

18.  Remove in the order indicated in the table.

19.  Install in the reverse order of removal.

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

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

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 Selector Cable Removal Note.)
4	Shift cable (See Shift Cable and Selector Cable Removal Note.)
5	Cable bracket
6	Pipe bracket
7	Clutch release cylinder bracket
8	Clutch release cylinder
9	Starter (See STARTER REMOVAL/INSTALLATION [MZR-CD 2.2].)
10	Transaxle mounting bolt (upper side)
11	Damper fork
12	Stabilizer control link
13	Tie-rod end ball joint (See FRONT CROSSMEMBER REMOVAL/INSTALLATION.)
14	Front lower arm
15	No.1 engine mount (See No.1 Engine Mount and No.4 Engine Mount Installation Note.)
16	Crossmember bracket
17	Crossmember component (See FRONT CROSSMEMBER REMOVAL/INSTALLATION.)
18	Drive shaft (LH) (See DRIVE SHAFT REMOVAL/INSTALLATION)
19	Drive shaft (RH) (See DRIVE SHAFT REMOVAL/INSTALLATION.)
20	Joint shaft (See JOINT SHAFT REMOVAL/INSTALLATION.)
21	GND wiring harness
22	No.4 engine mount bracket (See No.4 Engine Mount Removal Note.) (See No.1 Engine Mount and No.4 Engine Mount Installation Note.)
23	Transaxle mounting bolt (lower side)
24	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 SSTs.

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3.  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 SSTs 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 transaxle and temporarily tighten bolts A and B.

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2.  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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3.  Temporarily tighten bolt D with corn washer, and then the nuts in the order of E with corn washer, F.

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

5.  Tighten the bolt C.

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6.  Temporarily tighten the bolt G.

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

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8.  Tighten the bolt H.

9.  Tighten the bolt G.

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