Transmission Replacement

MANUAL TRANSAXLE ASSEMBLY








COMPONENTS

REPLACEMENT
1. PLACE FRONT WHEELS FACING STRAIGHT AHEAD
2. REMOVE FRONT WHEELS
3. REMOVE ENGINE UNDER COVER LH
4. REMOVE ENGINE UNDER COVER RH
5. REMOVE EXHAUST PIPE ASSEMBLY
6. DRAIN TRANSAXLE OIL
a. Remove the filler plug and gasket.
b. Remove the drain plug and gasket, and drain the oil.
c. Install the drain plug with a new gasket.
Torque: 39 Nm (400 kgf-cm, 29 ft. lbs.)
7. REMOVE HOOD SUB-ASSEMBLY
8. REMOVE CYLINDER HEAD COVER NO.2
9. REMOVE AIR CLEANER ASSEMBLY
10. REMOVE BATTERY CLAMP SUB-ASSEMBLY
11. REMOVE BATTERY
12. REMOVE BATTERY TRAY





13. REMOVE BATTERY CARRIER
a. Remove the 4 bolts and battery carrier.
14. REMOVE CRUISE CONTROL ACTUATOR ASSEMBLY (W/ CRUISE CONTROL)





15. DISCONNECT WIRE HARNESS
a. Disconnect the wire harness clamp.
b. Remove the 2 bolts and disconnect the 2 wire harness brackets.
c. Remove the bolt and disconnect the ground cable.





d. Remove the bolt and disconnect the ground cable.





16. DISCONNECT CONNECTOR
a. Disconnect the back-up lamp switch connector.





b. w/o ABS: Disconnect the speed sensor connector.





17. SEPARATE CLUTCH RELEASE CYLINDER ASSEMBLY
a. Remove the 5 bolts and separate the release cylinder assembly with the clutch piping from the transaxle.





18. SEPARATE FLOOR SHIFT CABLE TRANSMISSION CONTROL SHIFT
a. Remove the clip and washer and disconnect the shift cable from the transaxle.
b. Remove the clip and disconnect the shift cable from the bracket.





19. SEPARATE FLOOR SHIFT CABLE TRANSMISSION CONTROL SELECT
a. Remove the clip and washer and disconnect the select cable from the transaxle.
b. Remove the clip and disconnect the select cable from the bracket.





20. REMOVE STARTER ASSEMBLY
a. Remove the nut and disconnect the starter wire.
b. Disconnect the starter connector.
c. Remove the 2 bolts and starter assembly.
21. SEPARATE STEERING INTERMEDIATE SHAFT
22. REMOVE FRONT DRIVE SHAFT ASSEMBLY LH
SST 09520-01010, 09520-24010 (09520-32040)
23. REMOVE FRONT DRIVE SHAFT ASSEMBLY RH
SST 09520-01010, 09520-24010 (09520-32040)

HINT: Remove the RH side by following the same procedures as for the LH side.

24. SEPARATE RETURN TUBE SUB-ASSEMBLY
SST 09023-12701
25. SEPARATE PRESSURE FEED TUBE ASSEMBLY





26. SUSPEND ENGINE ASSEMBLY
a. Install the 2 hangers in the correct direction.
Parts No.:
Engine hanger: 12281-22021
No.1 engine hanger: 12281-15040
Bolt: 91512-131016
Torque: 38 Nm (387 kgf-cm, 28 ft. lbs.)
b. Attach the engine chain hoist to the hangers.

CAUTION: Do not attempt to hang the engine by hooking the chain to any other part.

27. REMOVE FRONT SUSPENSION CROSSMEMBER SUB-ASSEMBLY
28. SUPPORT MANUAL TRANSAXLE ASSEMBLY
a. Support the transaxle with a transmission jack.





29. REMOVE ENGINE MOUNTING INSULATOR LH
a. Remove the 5 bolts, nut and engine mounting insulator LH from the body.





30. REMOVE ENGINE MOUNTING BRACKET LH
a. Remove the 3 bolts and engine mounting bracket LH from the transaxle.





31. REMOVE MANUAL TRANSAXLE ASSEMBLY
a. Remove the 6 bolts and transaxle from the engine.





32. REMOVE ENGINE MOUNTING BRACKET FR
a. Remove the bolt, nut and engine mounting insulator FR from the engine mounting bracket FR.
b. Remove the 2 bolts and engine mounting bracket FR from the transaxle.





33. REMOVE ENGINE MOUNTING BRACKET RR
a. Remove the bolt and engine mounting insulator RR from the engine mounting bracket RR.
b. Remove the 3 bolts and engine mounting bracket RR from the transaxle.





34. INSTALL ENGINE MOUNTING BRACKET RR
a. Install the engine mounting bracket RR and 3 bolts to the transaxle.
Torque: 64 Nm (653 kgf-cm, 47 ft. lbs.)
b. Install the engine mounting insulator RR and bolt to the engine mounting bracket RR.
Torque: 65 Nm (663 kgf-cm, 48 ft. lbs.)





35. INSTALL ENGINE MOUNTING BRACKET FR
a. Install the engine mounting bracket FR and 2 bolts to the transaxle.
Torque: 64 Nm (653 kgf-cm, 47 ft. lbs.)
b. Install the engine mounting insulator FR, bolt and nut to the engine mounting bracket FR.
Torque: 52 Nm (530 kgf-cm, 38 ft. lbs.)





36. INSTALL MANUAL TRANSAXLE ASSEMBLY
a. Align the input shaft with the clutch disc and install the transaxle to the engine.
b. Install the 6 bolts.
Torque:
Bolt A: 64 Nm (650 kgf-cm, 47 ft. lbs.)
Bolt B: 47 Nm (480 kgf-cm, 35 ft. lbs.)
Bolt C: 23 Nm (230 kgf-cm, 17 ft. lbs.)





37. INSTALL ENGINE MOUNTING BRACKET LH
a. Install the engine mounting bracket LH to the transaxle with the 3 bolts.
Torque: 52 Nm (530 kgf-cm, 38 ft. lbs.)





38. INSTALL ENGINE MOUNTING INSULATOR LH
a. Install the engine mounting insulator LH with the 5 bolts and nut.
Torque:
Bolt A: 52 Nm (530 kgf-cm, 38 ft. lbs.)
Bolt B: 80 Nm (816 kgf-cm, 59 ft. lbs.)
39. INSTALL FRONT SUSPENSION CROSSMEMBER SUB-ASSEMBLY
SST 09670-00010
40. CONNECT STEERING INTERMEDIATE SHAFT
41. INSTALL COLUMN HOLE COVER SILENCER SHEET
42. CONNECT RETURN TUBE SUB-ASSEMBLY
SST 09023-12701
43. CONNECT PRESSURE FEED TUBE ASSEMBLY
SST 09023-12701
44. INSTALL FRONT DRIVE SHAFT ASSEMBLY LH
45. INSTALL FRONT DRIVE SHAFT ASSEMBLY RH

HINT: Install the RH side by following the same procedures as for the LH side.





46. INSTALL STARTER ASSEMBLY
a. Install the starter assembly and 2 bolts to the transaxle.
Torque: 37 Nm (378 kgf-cm, 27 ft. lbs.)
b. Connect the starter connector.
c. Install the wire and nut to the starter assembly.
Torque: 13 Nm (131 kgf-cm, 9 ft. lbs.)





47. CONNECT FLOOR SHIFT CABLE TRANSMISSION CONTROL SHIFT
a. Connect the shift cable end and install the washer and clip.
b. Install a new clip to the control cable bracket.





48. CONNECT FLOOR SHIFT CABLE TRANSMISSION CONTROL SELECT
a. Connect the select cable end and install the washer and clip.
b. Install a new clip to the control cable bracket.





49. CONNECT CLUTCH RELEASE CYLINDER ASSEMBLY
a. Install the release cylinder with the 5 bolts.
Torque:
Bolt A: 25 Nm (250 kgf-cm, 19 ft. lbs.)
Bolt B: 12 Nm (120 kgf-cm, 9 ft. lbs.)
Bolt C: 5.0 Nm (51 kgf-cm, 44 inch lbs.)





50. CONNECT CONNECTOR
a. Connect the back-up lamp switch connector.





b. w/o ABS: Connect the speed sensor connector.





51. CONNECT WIRE HARNESS
a. Install the 2 wire harness brackets to the transaxle with the 2 bolts.
Torque:
Bolt A: 26 Nm (260 kgf-cm, 19 ft. lbs.)
Bolt B: 13 Nm (131 kgf-cm, 9 ft. lbs.)
b. Connect the wire harness clamp.
c. Install the ground cable with the bolt.
Torque: 13 Nm (133 kgf-cm, 10 ft. lbs.)





d. Install the bolt and ground cable.
Torque: 13 Nm (133 kgf-cm, 10 ft. lbs.)
52. INSTALL CRUISE CONTROL ACTUATOR ASSEMBLY (W/ CRUISE CONTROL)





53. INSTALL BATTERY CARRIER
a. Install the battery carrier and 4 bolts.
Torque: 13 Nm (133 kgf-cm, 10 ft. lbs.)
54. INSTALL BATTERY TRAY
55. INSTALL BATTERY
56. INSTALL BATTERY CLAMP SUB-ASSEMBLY
Torque:
Bolt: 5.0 Nm (51 kgf-cm, 44 inch lbs.)
Nut: 3.5 Nm (36 kgf-cm, 31 inch lbs.)
57. INSTALL AIR CLEANER ASSEMBLY
Torque: 7.0 Nm (71 kgf-cm, 62 inch lbs.)
58. INSTALL CYLINDER HEAD COVER NO.2
Torque: 7.0 Nm (71 kgf-cm, 62 inch lbs.)
59. INSTALL HOOD SUB-ASSEMBLY
Torque: 13 Nm (133 kgf-cm, 10 ft. lbs.)
60. INSPECT HOOD SUB-ASSEMBLY
61. ADJUST HOOD SUB-ASSEMBLY
62. ADD TRANSAXLE OIL
63. INSPECT TRANSAXLE OIL
64. BLEED POWER STEERING FLUID
65. INSTALL FRONT WHEELS
Torque: 103 Nm (1,050 kgf-cm, 76 ft. lbs.)
66. PLACE FRONT WHEELS FACING STRAIGHT AHEAD
67. INSTALL EXHAUST PIPE ASSEMBLY
68. INSTALL ENGINE UNDER COVER LH
69. INSTALL ENGINE UNDER COVER RH
70. INSPECT FRONT WHEEL ALIGNMENT
71. CHECK ABS SPEED SENSOR SIGNAL (W/ ABS)