MANUAL TRANSAXLE REMOVAL/INSTALLATION [D66M-R]

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Removal

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

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

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 [D66M-R, D66MX-R].)

7.  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-D 2.2].)

•  Air cleaner cover

•  Air cleaner element

•  Fresh-air duct

•  Air cleaner case

•  Air hose

•  Resonance chamber

(2)  Remove the battery and battery tray. (See BATTERY REMOVAL/INSTALLATION [SKYACTIV-D 2.2].)

(3)  Disconnect the control cable from the manual transaxle. (See MANUAL TRANSAXLE SHIFT MECHANISM REMOVAL/INSTALLATION [D66M-R, D66MX-R].)

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

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

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(6)  Remove the air inlet pipe. (See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [SKYACTIV-D 2.2].)

(7)  Remove the nuts and set the turbocharger air outlet pipe component aside. (See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [SKYACTIV-D 2.2].)

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(8)  Drain the engine coolant. (See ENGINE COOLANT REPLACEMENT [SKYACTIV-D 2.2].)

(9)  Set the water pipe component aside. (See EGR COOLER REMOVAL/INSTALLATION [SKYACTIV-D 2.2].)

(10)  Remove the EGR pipe (EGR valve side). (See EGR PIPE REMOVAL/INSTALLATION [SKYACTIV-D 2.2].)

(11)  Remove the EGR cooler. (See EGR COOLER REMOVAL/INSTALLATION [SKYACTIV-D 2.2].)

(12)  Disconnect the neutral switch connector from the manual transaxle. (See NEUTRAL SWITCH REMOVAL/INSTALLATION [D66M-R, D66MX-R].)

(13)  Disconnect the back-up light switch connector from the manual transaxle. (See BACK-UP LIGHT SWITCH REMOVAL/INSTALLATION [D66M-R, D66MX-R].)

(14)  Disconnect the wiring harness from the manual transaxle, and set the wiring harness aside.

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(15)  Remove the brackets from the manual transaxle.

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

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

10.  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 front ABS wheel-speed sensors from the steering knuckles. (See FRONT ABS WHEEL-SPEED SENSOR REMOVAL/INSTALLATION.)

(3)  Disconnect the clip securing the brake hose from the front shock absorber. (See FRONT BRAKE HOSE REMOVAL/INSTALLATION.)

(4)  Disconnect the tie-rod end ball joints from the steering knuckles. (See FRONT CROSSMEMBER REMOVAL/INSTALLATION.)

(5)  Disconnect the front lower arms from the steering knuckles. (See FRONT CROSSMEMBER REMOVAL/INSTALLATION.)

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

(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.)

(9)  Remove the seal rubber.

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11.  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 [D66M-R, D66MX-R].)

(2)  Remove the starter. (See STARTER REMOVAL/INSTALLATION [SKYACTIV-D 2.2].)

(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 component from the manual transaxle.

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12.  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)  Remove the engine cover adapter.

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(4)  Install the SST to the position shown in the figure using the following bolt and washer.

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Bolt: part number 99794 1025 or an M10 × 1.25, length 25 mm {0.98 in}

Washer: approx. 3 mm {0.1 in} thickness

Tightening torque

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

(5)  Install the SST to the position shown in the figure using the following bolt.

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Bolt: part number 99794 1025 or an M10 × 1.25, length 25 mm {0.98 in}

Tightening torque

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

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

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(7)  As shown in the figure, set the front shafts of the SST to the left and right bolts.

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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.

13.  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	Stud bolt
4	Transaxle mounting bolt (lower side) (See Transaxle mounting bolt removal note.)
5	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.  Install the stud bolts to the manual transaxle.

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4.  Tighten the stud bolt for the manual transaxle.

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Note

•  If the No.4 engine mount bracket nut is loosened, tighten the stud bolts for the manual transaxle because they may be loosened.

5.  Install the No.4 engine mount bracket to No.4 engine mount rubber, and temporarily tighten the installation bolt.

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

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

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

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

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10.  Align the positions of the No.4 engine mount bracket installation nuts and bolt with the No.4 engine mount bracket.

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11.  Tighten the No.4 engine mount bracket installation nuts and bolts in the order shown in the figure.

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12.  Remove the SST (49 C017 5A0, 49 L017 5A0).

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

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

(1)  Install the starter. (See STARTER REMOVAL/INSTALLATION [SKYACTIV-D 2.2].)

(2)  Install the clutch release cylinder to the manual transaxle. (See CLUTCH RELEASE CYLINDER REMOVAL/INSTALLATION [D66M-R, D66MX-R].)

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

(1)  Install the seal rubber.

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

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

(4)  Connect the front stabilizer control links to the front stabilizer. (See FRONT STABILIZER INSTALLATION.)

(5)  Connect the front lower arms to the steering knuckles. (See FRONT CROSSMEMBER REMOVAL/INSTALLATION.)

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

(7)  Connect the clip securing the brake hose to the front shock absorber. (See FRONT BRAKE HOSE REMOVAL/INSTALLATION.)

(8)  Connect the front ABS wheel-speed sensors to the steering knuckles. (See FRONT ABS WHEEL-SPEED SENSOR REMOVAL/INSTALLATION.)

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

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

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

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

(1)  Install the engine cover adapter.

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(2)  Install the brackets to the manual transaxle.

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(3)  Connect the wiring harness to the manual transaxle.

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(4)  Connect the back-up light switch connector. (See BACK-UP LIGHT SWITCH REMOVAL/INSTALLATION [D66M-R, D66MX-R].)

(5)  Connect the neutral switch connector. (See NEUTRAL SWITCH REMOVAL/INSTALLATION [D66M-R, D66MX-R].)

(6)  Install the EGR cooler. (See EGR COOLER REMOVAL/INSTALLATION [SKYACTIV-D 2.2].)

(7)  Install the EGR pipe (EGR valve side). (See EGR PIPE REMOVAL/INSTALLATION [SKYACTIV-D 2.2].)

(8)  Connect the water pipe component. (See EGR COOLER REMOVAL/INSTALLATION [SKYACTIV-D 2.2].)

(9)  Install the turbocharger air outlet pipe component. (See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [SKYACTIV-D 2.2].)

(10)  Install the air inlet pipe. (See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [SKYACTIV-D 2.2].)

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

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

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(13)  Connect the control cable to the manual transaxle. (See MANUAL TRANSAXLE SHIFT MECHANISM REMOVAL/INSTALLATION [D66M-R, D66MX-R].)

(14)  Install the battery and battery tray. (See BATTERY REMOVAL/INSTALLATION [SKYACTIV-D 2.2].)

(15)  Install the following parts as a single unit. (See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [SKYACTIV-D 2.2].)

•  Air cleaner cover

•  Air cleaner element

•  Fresh-air duct

•  Air cleaner case

•  Air hose

•  Resonance chamber

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

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

21.  Refill the engine coolant. (See ENGINE COOLANT REPLACEMENT [SKYACTIV-D 2.2].)

22.  Add the specified amount of specified transaxle oil. (See MANUAL TRANSAXLE OIL REPLACEMENT [D66M-R, D66MX-R].)

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

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

25.  Install the engine cover. (See ENGINE COVER REMOVAL/INSTALLATION [SKYACTIV-D 2.2].)

26.  If the manual transaxle is overhauled, perform the “INSPECTION AFTER MANUAL TRANSAXLE OVERHAUL”. (See INSPECTION AFTER MANUAL TRANSAXLE OVERHAUL [D66M-R, D66MX-R].)