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 NO. 1 ENGINE UNDER COVER

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  4. REMOVE STARTER ASSEMBLY

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  5. REMOVE FRONT EXHAUST PIPE ASSEMBLY

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  6. REMOVE FRONT LOWER BUMPER ABSORBER

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  7. REMOVE REAR ENGINE UNDER COVER RH

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  8. REMOVE REAR ENGINE UNDER COVER LH

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  9. DRAIN MANUAL TRANSAXLE OIL

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  10. REMOVE DRIVE SHAFT ASSEMBLY

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  11. DRAIN ENGINE COOLANT

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  12. REMOVE NO. 1 ENGINE COVER

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  13. REMOVE AIR CLEANER CAP SUB-ASSEMBLY WITH AIR CLEANER HOSE ASSEMBLY

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  14. REMOVE AIR CLEANER CASE SUB-ASSEMBLY

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  15. REMOVE AIR CLEANER BRACKET

    1. C300396

      Disengage the 3 clamps to separate the wire harness.

    2. C300397

      Remove the 5 bolts and air cleaner bracket.

  16. DISCONNECT ENGINE WIRE

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  17. REMOVE NO. 4 WATER BY-PASS HOSE

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  18. DISCONNECT COMPRESSOR OUTLET ELBOW

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  19. DISCONNECT NO. 2 AIR HOSE

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  20. REMOVE NO. 1 AIR TUBE ASSEMBLY

    1. A337416

      Slide the clamp and disconnect the water by-pass hose assembly from the No. 2 radiator pipe.

    2. Slide the clamp and disconnect the radiator hose sub-assembly from the No. 1 radiator pipe.

    3. Disengage the clamp to disconnect the water hose sub-assembly from the compressor outlet elbow.

    4. Slide the clamp and disconnect the water hose sub-assembly from the No. 1 radiator pipe.

    5. Slide the clamp and disconnect the outlet heater water hose from the No. 2 radiator pipe.

    6. Remove the 2 bolts and No. 1 air tube assembly from the manual transaxle assembly.

  21. DISCONNECT TRANSMISSION CONTROL CABLE ASSEMBLY

    1. C300814

      Remove the 2 clips and disconnect the transmission control cable assembly from the manual transaxle assembly.

    2. C300815

      Remove the 2 clips and disconnect the transmission control cable assembly from the control cable bracket.

    3. C300816

      Remove the bolt to disconnect the bracket of the transmission control cable assembly from the rear engine mounting insulator.

  22. REMOVE NO. 1 CLUTCH HOUSING COVER

    1. C300406

      Remove the 2 bolts and No. 1 clutch housing cover.

  23. REMOVE NO. 2 MANIFOLD STAY

    1. C300407

      Using an E14 "TORX" socket wrench, remove the 2 bolts from the manual transaxle assembly.

    2. Remove the nut and No. 2 manifold stay.

  24. DISCONNECT CLUTCH RELEASE CYLINDER ASSEMBLY

    1. A318493

      Remove the 4 bolts to disconnect the clutch release cylinder assembly and clutch flexible hose bracket from the manual transaxle assembly.

  25. DISCONNECT WIRE HARNESS

    1. C300401

      Remove the bolt to disconnect the ground cable.

    2. C300400C01

      *a

      Back-up Light Switch Assembly Connector

      *b

      Neutral Position Switch Connector

      Disconnect the back-up light switch assembly connector.

    3. Disconnect the neutral position switch connector.

    4. Remove the 2 bolts to disconnect the wire harness.

  26. LOOSEN ENGINE AND TRANSAXLE CONNECTING BOLT

    1. Manual transaxle assembly upper side:

      1. C300409

        Using an E14 "TORX" socket wrench, loosen the 2 bolts.

    2. Manual transaxle assembly lower side:

      1. C300408

        Loosen the 4 bolts.

    3. Engine mounting insulator LH side:

      1. C300398

        Loosen the bolt.

  27. REMOVE FRONT SUSPENSION CROSSMEMBER SUB-ASSEMBLY

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  28. SUPPORT MANUAL TRANSAXLE ASSEMBLY

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

      Note:

      Secure the manual transaxle assembly to the transmission jack using a suitable adapter, such as a rope or attachment.

  29. REMOVE FRONT CROSS MEMBER SUB-ASSEMBLY

    1. C300950

      Remove the 6 bolts and front cross member sub-assembly.

  30. REMOVE FRONT ENGINE MOUNTING INSULATOR

    1. C301812

      Remove the through bolt, nut and front engine mounting insulator.

  31. REMOVE MANUAL TRANSAXLE ASSEMBLY

    • As there is very little space around the manual transaxle assembly, make sure that the manual transaxle assembly does not contact the vehicle body, clutch lines and radiator cooling fan when removing the manual transaxle assembly.

    • When removing the manual transaxle assembly, it is necessary to move the engine assembly and manual transaxle assembly up and down, and back and forth. Therefore, continually confirm that the parts are properly supported and stable while performing this procedure.

    1. C303129

      Remove the nut and through bolt to disconnect the engine mounting insulator LH from the engine mount bracket LH.

    2. Slowly lower the transmission jack to slightly tilt the engine assembly and manual transaxle assembly.

      Tip:

      Lower the engine assembly and manual transaxle assembly to a position where the engine mounting insulator LH can be removed.

    3. C300954

      Remove the 4 bolts and engine mounting insulator LH from the vehicle body.

    4. C197771

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

      Note:

      Make sure to clean the bolts and bolt holes after removing the manual transaxle assembly.

    5. C300953

      Use a cloth, etc. to protect the clutch lines as shown in the illustration.

    6. C332024C01

      *a

      Vehicle Body

      *b

      Crankshaft Damper Sub-assembly

      Slowly lower the transmission jack to slightly tilt the engine assembly and manual transaxle assembly.

      Note:

      Make sure that the crankshaft damper sub-assembly does not contact the vehicle body.

    7. C332025C01

      *a

      Engine Support Point

      Support the engine assembly with an engine lifter as shown in the illustration.

    8. C330944C02

      *a

      E14 "TORX" Bolt

      Using an E14 "TORX" socket wrench, remove the 2 bolts.

    9. Remove the 4 bolts.

    10. While making sure that the manual transaxle assembly does not contact the clutch lines, slowly separate the manual transaxle assembly from the engine assembly until the input shaft is clear of the diaphragm spring of the clutch cover.

      Note:

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

    11. Slowly lower the transmission jack to remove the manual transaxle assembly.

  32. REMOVE REAR ENGINE MOUNTING INSULATOR

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  33. REMOVE FRONT ENGINE MOUNTING BRACKET

    1. C300951

      Remove the 4 bolts and front engine mounting bracket.

  34. REMOVE REAR ENGINE MOUNTING BRACKET

    1. C366790

      Remove the 5 bolts and rear engine mounting bracket.