MANUAL TRANSAXLE ASSEMBLY REMOVAL


  1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL

  2. REMOVE STEERING COLUMN HOLE COVER PLATE

    A0136Y5

    1. Turn back the floor carpet and disengage the 2 claws from the steering hole cover plate.

  3. SEPARATE STEERING INTERMEDIATE SHAFT ASSEMBLY NO. 2

    A01369HE02

    1. Hold the steering wheel assembly with the seat belt in order to prevent rotation and damage to the spiral cable.

    2. A0137IGE05

      Place matchmarks on the sliding yoke sub-assembly and the intermediate shaft.

    3. Loosen bolt A and remove bolt B to separate the sliding yoke sub-assembly.

  4. SEPARATE STEERING COLUMN HOLE COVER SUB-ASSEMBLY NO. 1

    A0137CHE01

    1. Remove clip A and separate the steering column hole cover from the body.

      Note

      Do not damage clip B.

  5. REMOVE FRONT WHEELS

  6. DRAIN TRANSAXLE OIL


    1. Remove the filler plug and gasket.

    2. Remove the drain plug and gasket, and then drain the manual transaxle oil.

  7. REMOVE FRONT WIPER ARM HEAD CAP

    A0136ST

    1. Using a screwdriver with its tip wrapped in protective tape, remove the front wiper arm head cap.

  8. REMOVE FRONT WIPER ARM LH


    1. Operate the wiper, then stop the windshield wiper motor assembly in the automatic stop position.

    2. A013933

      Remove the nut and front wiper main arm.

    3. A0135UZ

      Disengage the meshing of the secondary arm from the front wiper motor and link assembly.

      Note

      Do not bend the secondary arm when removing it.

  9. REMOVE HOOD TO COWL TOP SEAL

    A01379NE01

    1. Disengage the 8 clips and remove the hood to cowl top seal.

  10. REMOVE COWL TOP VENTILATOR LOUVER LH

    A0136Y2E01

    1. Remove the clip.

    2. Disengage the 9 claws and remove the cowl top ventilator louver LH.

    3. Disconnect the washer hose.

  11. REMOVE COWL TOP VENTILATOR LOUVER RH

    A0136GYE01

    1. Remove the clip.

    2. Disengage the 8 claws and remove the cowl top ventilator louver RH.

    3. Disconnect the washer hose.

  12. REMOVE FRONT WIPER MOTOR AND LINK ASSEMBLY

    A0136OQ

    1. Remove the 2 bolts.

    2. Disconnect the connector and remove the front wiper motor and link assembly.

  13. REMOVE COWL TOP PANEL OUTER

    A01390L

    1. Remove the clamp of the wire harness.

    2. Remove the grommet of the wire harness.

    3. A01377P

      Remove the 10 bolts and cowl top panel.

  14. REMOVE BATTERY


    1. Loosen the nut and disconnect the battery positive terminal.

    2. A0136EQE01

      Remove the bolt and battery clamp.

    3. Remove the battery.

  15. SEPARATE ENGINE ROOM RELAY BLOCK

    A0138XK

    1. Remove the 2 bolts.

    2. Disengage the claw and separate the engine room relay block.

    3. A0136C9

      Provisionally set the relay block to the hood support rod.

  16. REMOVE BATTERY HOLD DOWN CLAMP


    1. Disengage the 2 wire harness clamps.

    2. A0135TU

      Remove the 3 bolts and battery clamp.

  17. REMOVE CLUTCH RELEASE FORK RETURN TENSION SPRING


    1. A0138ACE02
      Text in Illustration
      *1 Spring Hanger

      Remove the clutch release fork return tension spring from the spring hanger.

      Note


      • If there is any rust or deformation in the tension spring, replace it.

      • If there is any damage in the tension spring damper, replace it.

  18. SEPARATE TRANSMISSION CONTROL CABLE ASSEMBLY

    A0135UNE01

    1. Remove the clip A and clip B, then separate the transmission shift cable from the manual transaxle.

    2. A0136KNE01

      Remove the clip A and clip B, then separate the transmission select cable from the manual transaxle.

  19. SEPARATE CLUTCH RELEASE CABLE ASSEMBLY

    A01391E

    1. Turn and loosen the clutch release cable adjusting nut.

    2. A01391Y

      Separate the clutch release cable from the manual transaxle.

  20. DISCONNECT WIRING HARNESS CLAMP BRACKET


    1. Disconnect the back-up light switch connector.

    2. Disconnect the oxygen sensor connector.

    3. A0138M6

      Remove the bolt and disconnect the wiring harness bracket.

  21. DISCONNECT ENGINE WIRE NO.3

    A01362O

    1. Remove the 2 bolts and disconnect the engine wire No. 3 (ground cable).

  22. REMOVE FLYWHEEL HOUSING UNDER COVER

    A0138XW

    1. Remove the 3 bolts and flywheel housing under cover.

  23. REMOVE STARTER ASSEMBLY


    1. A01374KE01

      Open the terminal cap, remove the nut and disconnect the wire harness from terminal 50.

    2. Open the terminal cap, remove the nut and disconnect the wire harness from terminal 30.

    3. Remove the bolt, and wire harness clamp.

    4. Remove the 2 bolts, and the starter.

  24. REMOVE EXHAUST PIPE ASSEMBLY FRONT


    1. Remove the bolt and clamp.

    2. Remove the 2 bolts, 2 compression springs and exhaust pipe gasket.

    3. Remove the exhaust pipe No.4 support and exhaust front pipe assembly.

      A0135VGE02

  25. SEPARATE SPEED SENSOR FRONT LH

    Click here

  26. SEPARATE SPEED SENSOR FRONT RH

    Tech Tips

    The separation procedure for the RH side is the same as that for the LH side.

  27. REMOVE FRONT AXLE SHAFT LH NUT

    A0135U4E01

    1. Using SST and a hammer, release the staked part of the front axle hub nut.

      SST
      09930-00010

      Note

      Release the staked part of the lock nut completely. Otherwise, the screw of the drive shaft may be damaged.

    2. While applying the brake, remove the front axle hub nut.

  28. REMOVE FRONT AXLE SHAFT RH NUT

    Tech Tips

    The removal procedure for the RH side is the same as that for the LH side.

  29. SEPARATE TIE ROD END SUB-ASSEMBLY LH


    1. Remove the cotter pin and castle nut.

    2. A0136K6E01

      Install SST (spacer B) to the threaded section of the tie rod end.

      SST
      09960-20010   ( 09961-02060 )

      Tech Tips

      Make sure the upper ends of the threaded section of the tie rod end and SST (spacer B) are aligned.

    3. Using SST, separate the tie rod end from the front axle assembly.

      A0137FRE01
      SST
      09960-20010   ( 09961-02010 )

      Note


      • Make sure to tie the string of SST to the vehicle to prevent SST from dropping.

      • Install SST so that A and B are parallel.

      • Be sure to place the wrench on the part indicated in the illustration.

      • Do not damage the ball joint dust cover.

      • Do not damage the front disc brake dust cover.

  30. SEPARATE TIE ROD END SUB-ASSEMBLY RH

    Tech Tips

    The separation procedure for the RH side is the same as that for the LH side.

  31. REMOVE FRONT STABILIZER BAR

    A013602E02

    1. Hold the bolt with a spanner (10 mm) and remove the nut.

    2. Remove the 2 cushion retainers and 2 cushions, and separate the front stabilizer bar.

  32. SEPARATE FRONT SUSPENSION ARM SUB-ASSEMBLY LOWER NO. 1 LH


    1. Remove the clip and castle nut.

    2. A0135XUE01

      Install SST (spacer B) to the threaded section of the lower ball joint.

      SST
      09960-20010   ( 09961-02060 )

      Tech Tips

      Make sure the upper ends of the threaded section of the lower ball joint and SST (spacer B) are aligned.

    3. Using SST, separate the lower arm.

      A0136IYE01
      SST
      09960-20010   ( 09961-02010 )

      Note


      • Make sure to tie the string of SST to the vehicle to prevent SST from dropping.

      • Install SST so that A and B are parallel.

      • Be sure to place the wrench on the part indicated in the illustration.

      • Do not damage the lower ball joint dust cover.

      • Do not damage the drive shaft outboard joint boots.

      • Do not damage the front disc brake dust cover.

  33. SEPARATE FRONT SUSPENSION ARM SUB-ASSEMBLY LOWER NO.1 RH

    Tech Tips

    The separation procedure for the RH side is the same as that for the LH side.

  34. REMOVE FRONT AXLE ASSEMBLY LH


    1. Using a plastic hammer, tap the end of the front drive shaft assembly and disengage the fitting between the front drive shaft assembly and front axle assembly.

      Tech Tips

      If it is difficult to disengage the fitting, tap the end of the front drive shaft assembly with a brass bar and hammer.

    2. Push the front axle assembly out of the vehicle to remove the front drive shaft assembly from the front axle assembly.

      Note


      • Do not push the front axle assembly further out of the vehicle than is necessary.

      • Do not damage the front axle outboard joint boot.

      • Do not damage the speed sensor rotor.

      • Hang the front drive shaft assembly down with a piece of string or equivalent.

      • When removing the drive shaft, do not hit the sensor with it.

  35. REMOVE FRONT AXLE ASSEMBLY RH

    Tech Tips

    The removal procedure for the RH side is the same as that for the LH side.

  36. REMOVE FRONT DRIVE SHAFT ASSEMBLY LH

    A0138W1

    1. Using a screwdriver and hammer, remove the front drive shaft assembly.

      Note


      • Do not damage the oil seal or the boot.

      • Do not drop the drive shaft assembly.

  37. REMOVE FRONT DRIVE SHAFT ASSEMBLY RH

    Tech Tips

    The removal procedure for the RH side is the same as that for the LH side.

  38. SUSPEND ENGINE ASSEMBLY


    1. for 1KR-FE:


      1. A0138E2E03

        Install the No. 1 and No. 2 engine hangers, oriented in the correct directions.

        Part No.
        No. 1 engine hanger : 12281 - 40030
        No. 2 engine hanger : 12282 - 40010
        Bolt
        91671 - 80820
        Torque:
        28 N*m  { 286 kgf*cm, 21 ft.*lbf }
      2. A0136T1

        Attach the engine sling device to the engine hangers.

        CAUTION:

        Do not hang the engine by hooking the chain to any other parts.

    2. for 2WZ-TV:


      1. A0135WG

        Attach the engine sling device and suspend the engine with the chain block.

  39. REMOVE FRONT SUSPENSION CROSSMEMBER SUB-ASSEMBLY


    1. A0137IIE02

      Remove the 3 bolts, then separate the engine mounting control bracket (for 1KR-FE).

    2. A0137Q9

      Remove the bolt, then separate the control rod from the engine mounting control bracket (for 2WZ-TV).

    3. A0138HU

      Using a transmission jack, support the front suspension crossmember sub-assembly.

    4. A0138F6E02

      Remove the 6 bolts and the front suspension crossmember sub-assembly.

  40. SUPPORT MANUAL TRANSAXLE ASSEMBLY


    1. Support the manual transaxle with a transmission jack.

  41. REMOVE ENGINE MOUNTING INSULATOR LH

    A0138IH

    1. Remove the 7 bolts and engine mounting insulator with the engine mounting bracket.

  42. REMOVE MANUAL TRANSAXLE ASSEMBLY

    A013625

    1. Remove the 5 bolts and manual transaxle from the engine.