MANUAL TRANSAXLE REMOVAL/INSTALLATION [C66M-R]

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Caution

•  Performing the following procedures could cause an open circuit in the front ABS wheel-speed sensor wiring harness if it is pulled by mistake. Before servicing, disconnect the front ABS wheel-speed sensor and set it aside so that the wiring harness will not be pulled by mistake.

•  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.

Removal

1.  Disconnect the negative battery terminal. (See NEGATIVE BATTERY TERMINAL DISCONNECTION/CONNECTION.)

2.  Remove the plug hole plate. (See PLUG HOLE PLATE REMOVAL/INSTALLATION [SKYACTIV-G 2.0, SKYACTIV-G 2.5 (WITHOUT CYLINDER DEACTIVATION)].)

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

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

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

6.  Drain the manual transaxle oil. (See MANUAL TRANSAXLE OIL REPLACEMENT [C66M-R].)

7.  Drain the engine coolant. (See ENGINE COOLANT REPLACEMENT [SKYACTIV-G 2.0, SKYACTIV-G 2.5 (WITHOUT CYLINDER DEACTIVATION)].)

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

(1)  Remove the following parts as a single unit. (See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [SKYACTIV-G 2.0, SKYACTIV-G 2.5 (WITHOUT CYLINDER DEACTIVATION)].)

•  Air cleaner cover

•  Air cleaner element

•  Fresh-air duct

•  Air cleaner case

•  Air hose

•  Resonance chamber

(2)  Remove the battery. (See BATTERY REMOVAL/INSTALLATION [SKYACTIV-G 2.0, SKYACTIV-G 2.5 (WITHOUT CYLINDER DEACTIVATION)].)

(3)  Remove the PCM component. (See PCM REMOVAL/INSTALLATION [SKYACTIV-G 2.0, SKYACTIV-G 2.5 (WITHOUT CYLINDER DEACTIVATION)].)

(4)  Remove the battery tray. (See BATTERY REMOVAL/INSTALLATION [SKYACTIV-G 2.0, SKYACTIV-G 2.5 (WITHOUT CYLINDER DEACTIVATION)].)

(5)  Disconnect the control cable from the manual transaxle. (See MANUAL TRANSAXLE SHIFT MECHANISM REMOVAL/INSTALLATION [C66M-R].)

(6)  Remove the control cable bracket from the manual transaxle.

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

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(8)  Remove the bracket from the manual transaxle and the exhaust manifold.

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(9)  Disconnect the neutral switch connector from the manual transaxle. (See NEUTRAL SWITCH REMOVAL/INSTALLATION [C66M-R].)

(10)  Disconnect the back-up light switch connector from the manual transaxle. (See BACK-UP LIGHT SWITCH REMOVAL/INSTALLATION [C66M-R].)

(11)  Remove the lower radiator hose component. (See RADIATOR REMOVAL/INSTALLATION [SKYACTIV-G 2.0, SKYACTIV-G 2.5 (WITHOUT CYLINDER DEACTIVATION)].) (See COOLANT CONTROL VALVE REMOVAL/INSTALLATION [SKYACTIV-G 2.0, SKYACTIV-G 2.5 (WITHOUT CYLINDER DEACTIVATION)].)

(12)  Remove the bolts and set the wiring harness and wiring harness brackets in a place which does not interfere with servicing.

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9.  Remove the joint cover. (See STEERING WHEEL AND COLUMN REMOVAL/INSTALLATION.)

10.  Disconnect the intermediate shaft from the steering gear and linkage. (See STEERING WHEEL AND COLUMN REMOVAL/INSTALLATION.)

11.  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 FRONT BRAKE HOSE 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.)

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

(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 manual transaxle. (See FRONT DRIVE SHAFT REMOVAL/INSTALLATION.)

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

12.  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 [C66M-R].)

(2)  Remove the starter. (See STARTER REMOVAL/INSTALLATION [SKYACTIV-G 2.0, SKYACTIV-G 2.5 (WITHOUT CYLINDER DEACTIVATION)].)

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

(4)  Remove the No.1 engine mount bracket from the manual transaxle.

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13.  Install the SST using the following procedure:

Caution

•  Refer to the SST 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.

(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 using a bolt with part number 99794 1025 or an M10—1.25, length 25 mm {0.98 in} bolt, and a washer 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 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 to the left and right bolts.

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(7)  To prevent interference of the SST with the hose when assembling the SST (49 L017 5A0), disconnect the hose clip from the bracket shown in the figure and set the fuel hose and vacuum hose aside.

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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.

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

14.  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	Transaxle mounting bolt (lower side) (See Transaxle mounting bolt removal note.)
4	Manual transaxle

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 manual transaxle carefully, holding it steady. If the manual transaxle falls it could be damaged or cause injury.

1.  Adjust the SST and lean the engine toward the manual transaxle.

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2.  Support the manual transaxle on a jack.

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

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4.  Remove the manual transaxle.

Installation

Warning

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

1.  Set the manual transaxle on a jack and lift into place.

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

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3.  Measure the projection of the stud bolts.

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Note

•  If the projection amount is not within the range, adjust the projection amount of the stud bolts.

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.  Lift up the manual transaxle using the SSTs, pass the manual transaxle stud bolts through the No.4 engine mount bracket, and temporarily tighten the No.4 engine mount installation nuts.

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6.  Install the No.1 engine mount bracket, and tighten the installation bolts in the order shown in the figure.

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

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

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

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

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11.  Remove the SST (49 C017 5A0).

12.  Tighten the No.1 engine mount rubber installation bolts in the order shown in the figure.

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

(1)  Install the starter. (See STARTER REMOVAL/INSTALLATION [SKYACTIV-G 2.0, SKYACTIV-G 2.5 (WITHOUT CYLINDER DEACTIVATION)].)

(2)  Install the clutch release cylinder to the manual transaxle. (See CLUTCH RELEASE CYLINDER REMOVAL/INSTALLATION [C66M-R].)

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

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

(2)  Connect the front drive shaft (LH) to the manual transaxle. (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 INSTALLATION.)

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

(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 FRONT BRAKE HOSE REMOVAL/INSTALLATION.)

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

15.  Connect the intermediate shaft to the steering gear and linkage. (See STEERING WHEEL AND COLUMN REMOVAL/INSTALLATION.)

16.  Install the joint cover. (See STEERING WHEEL AND COLUMN REMOVAL/INSTALLATION.)

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

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

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(2)  Connect the clip shown in the figure.

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(3)  Install the wiring harness brackets.

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(4)  Install the lower radiator hose component. (See RADIATOR REMOVAL/INSTALLATION [SKYACTIV-G 2.0, SKYACTIV-G 2.5 (WITHOUT CYLINDER DEACTIVATION)].) (See COOLANT CONTROL VALVE REMOVAL/INSTALLATION [SKYACTIV-G 2.0, SKYACTIV-G 2.5 (WITHOUT CYLINDER DEACTIVATION)].)

(5)  Connect the back-up light switch connector. (See BACK-UP LIGHT SWITCH REMOVAL/INSTALLATION [C66M-R].)

(6)  Connect the neutral switch connector. (See NEUTRAL SWITCH REMOVAL/INSTALLATION [C66M-R].)

(7)  Install the bracket to the manual transaxle and the exhaust manifold using the following procedure:

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1)  Tighten the bolt A.

Tightening torque

8—10 N·m {82—101 kgf·cm, 71—88 in·lbf}

2)  Temporarily tighten the bolt B and C.

3)  Tighten the bolt B.

Tightening torque

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

4)  Tighten the bolt C.

Tightening torque

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

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

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(9)  Install the control cable bracket to the manual transaxle.

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(10)  Connect the control cable to the manual transaxle. (See MANUAL TRANSAXLE SHIFT MECHANISM REMOVAL/INSTALLATION [C66M-R].)

(11)  Install the battery tray. (See BATTERY REMOVAL/INSTALLATION [SKYACTIV-G 2.0, SKYACTIV-G 2.5 (WITHOUT CYLINDER DEACTIVATION)].)

(12)  Install the PCM component. (See PCM REMOVAL/INSTALLATION [SKYACTIV-G 2.0, SKYACTIV-G 2.5 (WITHOUT CYLINDER DEACTIVATION)])

(13)  Install the battery. (See BATTERY REMOVAL/INSTALLATION [SKYACTIV-G 2.0, SKYACTIV-G 2.5 (WITHOUT CYLINDER DEACTIVATION)].)

(14)  Install the following parts as a single unit. (See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [SKYACTIV-G 2.0, SKYACTIV-G 2.5 (WITHOUT CYLINDER DEACTIVATION)].)

•  Air cleaner cover

•  Air cleaner element

•  Fresh-air duct

•  Air cleaner case

•  Air hose

•  Resonance chamber

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

19.  Refill the engine coolant. (See ENGINE COOLANT REPLACEMENT [SKYACTIV-G 2.0, SKYACTIV-G 2.5 (WITHOUT CYLINDER DEACTIVATION)].)

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 [C66M-R].)

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

23.  Connect the negative battery terminal. (See NEGATIVE BATTERY TERMINAL DISCONNECTION/CONNECTION.)

24.  Install the plug hole plate. (See PLUG HOLE PLATE REMOVAL/INSTALLATION [SKYACTIV-G 2.0, SKYACTIV-G 2.5 (WITHOUT CYLINDER DEACTIVATION)].)

25.  If the manual transaxle is overhauled, perform the “INSPECTION AFTER MANUAL TRANSAXLE OVERHAUL”. (See INSPECTION AFTER MANUAL TRANSAXLE OVERHAUL [C66M-R].)