Transmission Removal

Manual Transmission Assembly

REMOVAL
1. Open the front hood fully, and support with stay or the air intake chamber.
2. Disconnect ground cable from battery.
3. Remove the air intake duct and cleaner case or the air intake chamber. (Non-TURBO model)





4. Remove the air cleaner case stay. (Non-TURBO model)
5. Remove the intercooler. (Turbo model)





6. Disconnect the following connectors:
1. Neutral position switch connector
2. Back-up light switch connector
3. Vehicle speed sensor
7. Remove the starter.
8. Remove the operating cylinder from transmission.





^ NON-TURBO MODEL





^ TURBO MODEL





9. Remove the pitching stopper.





10. Set the ST.
ST 41099AA000 ENGINE SUPPORT ASSY
11. Separate the clutch release fork from release bearing. (Turbo model)
1. Remove the clutch operating cylinder from transmission.





2. Remove the plug using 10 mm hexagon wrench.





3. Screw the 6 mm dia. bolt into release fork shaft, and then remove it.
4. Raise the release fork and unfasten the release bearing tabs to free release fork.

NOTE: Step (4) is required to prevent interference with engine when removing the engine from transmission.





12. Remove the bolt which holds the right upper side of transmission to engine.
13. Remove the front and center exhaust pipes. (Non-TURBO model)
14. Remove the center exhaust pipe. (Turbo model).
15. Remove the rear exhaust pipe and muffler.

CAUTION: When removing the exhaust pipes, be careful each exhaust pipe does not drop out.

16. Remove the heat shield cover. (If equipped)





17. Remove the hanger bracket from right side of transmission.

18. Remove the propeller shaft.





19. Remove the gear shift rod and stay from transmission.
1. Disconnect the stay from transmission.
2. Disconnect the rod from transmission.





20. Disconnect the stabilizer link from transverse link.
21. Remove the bolt securing ball joint of transverse link to housing.
22. Separate the front drive shafts from transmission.





23. Remove the nuts which hold the lower side of transmission to engine.





24. Place the transmission jack under transmission.

CAUTION: Always support the transmission case with a transmission jack.





25. Remove the transmission rear crossmember from vehicle.





26. While compressing turn buckle of engine support assembly, bring down transmission jack and then tilt engine and transmission.
ST 41099AA000 ENGINE SUPPORT ASSY
27. Remove the transmission.

NOTE: Move the transmission jack toward rear until mainshaft is withdrawn from clutch cover.

28. Separate the transmission assembly and rear cushion rubber.
29. Remove the clutch release bearing from engine side. (Turbo model)