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MANUAL TRANSAXLE REMOVAL/INSTALLATION [A26M-R]

id051520800600

1. Remove the following parts:

  (1) Battery and battery tray.
  (2) Air cleaner component.
  (See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [MZR-CD (RF Turbo)].)
  (3) Air hose above the transaxle.
  (See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [MZR-CD (RF Turbo)].)
  (4) Air pipe above the transaxle.
  (See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [MZR-CD (RF Turbo)].)
  (5) Turbocharger air outlet pipe.
  (See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [MZR-CD (RF Turbo)])
  (6) EGR cooler
  (See EGR COOLER REMOVAL/INSTALLATION [MZR-CD (RF Turbo)])
  (7) Wheels, tires and splash shields.
  (8) Under cover.

2. Remove the steering gear and linkage, and pipe assembly installation bolts from the front crossmember, then suspend the steering gear and linkage with a cable.

(See STEERING GEAR AND LINKAGE REMOVAL/INSTALLATION [MZR-CD (RF Turbo)].)

Tightening torque

  • Pipe assembly: 7.8-10.8 N·m {79.6-110.0 kgf·cm, 69.1-95.5 in·lbf}

3. Remove the front auto leveling sensor.

(See FRONT AUTO LEVELING SENSOR REMOVAL/INSTALLATION.)

4. Drain the transaxle oil into a suitable container.

5. Remove in the order indicated in the table.

6. Install in the reverse order of removal.

7. Adjust the headlight zeroset. (See HEADLIGHT ZEROSET.)

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

9. Warm up the engine and transaxle, inspect for oil leakage, and inspect the transaxle operation.

  Warning

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

  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].)

.

1 | Shift cable (See Shift Cable And Select Cable Removal Note.)
2 | Select cable (See Shift Cable And Select Cable Removal Note.)
3 | Neutral switch connector
4 | Back-up light switch connector
5 | GND harness
6 | Crank angle sensor harness
7 | Transaxle mounting bolt (upper side)
8 | Starter (See STARTER REMOVAL/INSTALLATION [MZR-CD (RF Turbo)])
9 | Clutch release cylinder, clutch pipe component
10 | Tie-rod end ball joint (See STEERING GEAR AND LINKAGE REMOVAL/INSTALLATION [MZR-CD (RF Turbo)].)
11 | Damper fork
12 | Stabilizer control link
13 | Lower arm (front, rear) ball joint (See FRONT LOWER ARM (FRONT) REMOVAL/INSTALLATION.) (See FRONT LOWER ARM (REAR) REMOVAL/INSTALLATION.)
14 | No.1 engine mount (See No.4 and No.1 Engine Mount Installation Note)
15 | Crossmember bracket
16 | Crossmember component (See FRONT CROSSMEMBER REMOVAL/INSTALLATION.)
17 | Drive shaft (left side) (See FRONT DRIVE SHAFT REMOVAL/INSTALLATION [L8, LF, L3, MZR-CD (RF Turbo)].)
18 | Drive shaft (right side) (See FRONT DRIVE SHAFT REMOVAL/INSTALLATION [L8, LF, L3, MZR-CD (RF Turbo)].)
19 | Joint shaft (See JOINT SHAFT REMOVAL/INSTALLATION [L8, LF, L3, MZR-CD (RF Turbo)].)
20 | No.4 engine mount bracket (See No.4 and No.1 Engine Mount Installation Note)
21 | Stud bolt (See Manual Transaxle Removal Note.) (See Manual Transaxle Installation Note.)
22 | Transaxle mounting bolt (lower side)
23 | Manual transaxle (See Manual Transaxle Removal Note) (See Manual Transaxle Installation Note)

## Shift Cable And Select Cable Removal Note

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

## 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.

  (1) Install the right rear shaft of the SST to the bolt of the right shock absorber as shown in the figure.
  (2) Install the left rear shaft of the SST to the bolt of the left shock absorber. (Identical position to the right side)
  (3) Install the left/right front shaft of the SST with front foot No.2 to the bolt as shown in the figure.
  (4) Adjust the positions of the SST side bars so that they are the same height (left and right) and horizontal.
  (5) Make sure each joint is securely tightened.

2. Support the engine using the SST.

  Note

  • The SST (49E 017 5A0) can be used in place of the SST (49C 017 5A0).

3. Remove the battery tray bracket, No.4 engine mount bracket.

## Manual Transaxle Removal Note

1. Remove the stud of the No.4 engine mount.

2. Loosen the SST (49 C017 5A0) and lean the engine toward the transaxle.

3. Support the transaxle on a jack.

4. Remove the transaxle mounting bolts.

5. Remove the transaxle.

## Manual Transaxle Installation Note

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

2. Install the transaxle mounting bolts.

3. Install the stud of the No.4 engine mount.

Tightening torque

  27.4-40.2 N·m
  {2.80-4.09 kgf·m, 20.2-29.6 ft·lbf}

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

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

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

2. Lightly tighten the nuts D, E and bolt F.

3. Set the transaxle on a garage jack and lift it.

4. Align the hole of the No.4 engine mount bracket and rubber.

5. Through the bolt G to the hole of the No.4 engine mount, and then lightly tighten the bolt.

6. Tighten the nuts and bolt to the specified torque in the order of D, E, F.

Tightening torque

  D, E, F: 66.6-93.1 N·m
  {6.8-9.4 kgf·m, 50-68 ft·lbf}

7. Install the No.1 engine mount rubber.

8. Tighten the bolts to the specified torque in the order of A, B.

Tightening torque

  A, B: 93.1-116.6 N·m
  {9.50-11.88 kgf·m, 68.66-85.98 ft·lbf}

9. Align the hole of the No.1 engine mount rubber with the crossmember.

10. Lightly tighten the bolt C.

11. Tighten the bolt G of the No.4 engine mount to the specified torque.

Tightening torque

  E: 85.3-116.6 N·m
  {8.70-11.88 kgf·m, 62.91-85.98 ft·lbf}

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

13. Tighten the bolt C of the No.1 engine mount to the specified torque.

Tightening torque

  C: 93.1-116.6 N·m
  {9.50-11.88 kgf·m, 68.66-85.98 ft·lbf}