MANUAL TRANSAXLE ASSEMBLY REMOVAL

PROCEDURE

  1. PRECAUTION

    Note:

    After turning the ignition switch off, waiting time may be required before disconnecting the cable from the negative (-) battery terminal. Therefore, make sure to read the disconnecting the cable from the negative (-) battery terminal notices before proceeding with work.

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  2. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL

    Note:

    When disconnecting the cable, some systems need to be initialized after the cable is reconnected.

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  3. REMOVE BATTERY

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  4. REMOVE AIR CLEANER CASE SUB-ASSEMBLY

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  5. DISCONNECT TRANSMISSION CONTROL CABLE ASSEMBLY

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  6. SEPARATE NO. 1 ENGINE ROOM RELAY BLOCK

    1. A322375

      Remove the No. 1 engine room relay block cover.

    2. C304059

      Remove the 2 bolts.

    3. Disengage the wire harness clamp and disconnect the wire harness from the battery clamp sub-assembly.

    4. Disengage the claw and separate the No. 1 engine room relay block from the battery clamp sub-assembly.

  7. REMOVE BATTERY CLAMP SUB-ASSEMBLY

    1. Remove the 3 bolts.

    2. C304060

      Disengage the 3 wire harness clamps to disconnect the wire harness from the battery clamp sub-assembly.

  8. REMOVE SHIFT AND SELECT LEVER BUSH

    1. C308683

      Remove the bolt and shift and select lever bush from the manual transaxle assembly.

  9. DISCONNECT WIRE HARNESS

    1. C304070

      Disconnect the back-up light switch assembly connector.

    2. C304064

      Remove the 2 nuts and wire harness bracket from the manual transaxle assembly.

    3. C304061

      Remove the bolt and No. 3 engine wire from the manual transaxle assembly.

    4. Disengage the wire harness clamp to disconnect the No. 3 engine wire from the clutch cable bracket.

  10. DISCONNECT CLUTCH RELEASE CABLE ASSEMBLY

    1. C305290C01

      *1

      Clutch Release Fork Sub-assembly

      *a

      Push

      *b

      Turn

      While pushing the clutch release fork sub-assembly, turn and loosen the clutch release cable end clamp.

    2. C304521

      Disconnect the clutch release cable assembly from the manual transaxle assembly.

  11. DISCONNECT NO. 2 RADIATOR HOSE

    1. C304062

      Disconnect the No. 2 radiator hose from the clutch cable bracket.

  12. REMOVE CLUTCH CABLE BRACKET

    1. C304063

      Remove the 2 bolts and clutch cable bracket from the manual transaxle assembly.

  13. DRAIN MANUAL TRANSAXLE OIL

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  14. REMOVE FRONT EXHAUST PIPE ASSEMBLY

    1. Remove the nut from the exhaust pipe support.

    2. C304065

      Remove the 2 nuts, 2 spacers and 2 clamps from the front exhaust pipe assembly.

    3. Remove the front exhaust pipe assembly from the exhaust manifold, exhaust pipe support and tail exhaust pipe assembly.

  15. REMOVE FRONT DRIVE SHAFT ASSEMBLY

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  16. REMOVE CONTROL CABLE BRACKET

    1. C304126

      Remove the 2 bolts and control cable bracket from the manual transmission assembly.

  17. REMOVE STARTER ASSEMBLY

    1. A324258

      Using a 6 mm hexagon wrench, remove the bolt.

    2. A324261C01

      *a

      Tab

      *b

      Starter Assembly Connector

      *c

      Nut

      Pull out the tabs as shown in the illustration and disconnect the starter assembly connector.

      Note:

      To prevent damage to the connector, do not pull out the tabs excessively.

    3. Remove the nut and disconnect terminal 30.

    4. A324260

      Using a 6 mm hexagon wrench, remove the 2 bolts and starter assembly.

  18. DISCONNECT FRONT FENDER LINER LH

    1. C302674C01
      V100135

      Bolt
      V100136

      Screw

      Remove the 2 screws and 3 bolts to disconnect the front fender liner LH.

  19. SUPPORT ENGINE ASSEMBLY

    1. C304083

      Remove the 3 bolts from the engine assembly.

    2. C304074C01

      *a

      Attachment Installation Position

      Support the engine assembly with an engine lifter.

  20. SUPPORT MANUAL TRANSAXLE ASSEMBLY

    1. Support the manual transaxle assembly with a transmission jack.

  21. REMOVE ENGINE MOUNTING CONTROL BRACKET

    1. C304085

      Remove the 3 bolts and engine mounting control bracket from the manual transaxle assembly.

  22. REMOVE ENGINE MOVING CONTROL ROD

    1. C304084

      Remove the bolt and engine moving control rod from the front suspension crossmember sub-assembly.

  23. REMOVE ENGINE MOUNTING INSULATOR LH

    1. C304075

      Disconnect the clutch release cable assembly from the clutch release cable clamp.

    2. C305349

      Remove the bolt and clutch release cable clamp from the engine mounting insulator LH.

    3. C304076

      Remove the 6 bolts and engine mounting insulator LH from the vehicle body and engine mounting bracket LH.

  24. REMOVE ENGINE MOUNTING BRACKET LH

    1. C304077

      Remove the 4 bolts and engine mounting bracket LH from the manual transaxle assembly.

  25. REMOVE MANUAL TRANSAXLE ASSEMBLY

    1. C304078C03
      V100135

      Bolt
      V100136

      Nut

      Remove the 2 bolts and 2 nuts.

    2. Remove the manual transaxle assembly as shown in the illustration.

      CAUTION:

      When rotating and removing the manual transaxle assembly, do not allow it to contact any surrounding parts or drop from the transmission jack.

      Note:

      • To prevent damage to the 2 knock pins, do not pry between the manual transaxle assembly and engine assembly.

      • Do not apply excessive force to the manual transaxle assembly as this will break the input shaft.

      • Be careful not to damage the No. 2 radiator hose and fan shroud assembly when removing the manual transaxle assembly.

      C304095C01

      *a

      Top View

      *b

      Pull the manual transaxle assembly toward the outside of the vehicle.

      *c

      Move the manual transaxle assembly toward the front of the vehicle.

      *d

      Rotate the manual transaxle assembly.

      Remove the manual transaxle assembly.