MANUAL TRANSAXLE ASSEMBLY REMOVAL

PROCEDURE

  1. PRECAUTION

    Note:

    After turning the ignition switch off, waiting time may be required before disconnecting the cable from battery terminal. Therefore, make sure to read the disconnecting the cable from the battery terminal notice 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 NO. 2 ENGINE UNDER COVER

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  5. REMOVE STARTER ASSEMBLY

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  6. REMOVE EXHAUST PIPE ASSEMBLY

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  7. REMOVE REAR ENGINE UNDER COVER LH

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  8. REMOVE REAR ENGINE UNDER COVER RH

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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. C341123

      Disconnect the 3 clamps and wire harness.

    2. C341124

      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

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  21. DISCONNECT TRANSAXLE CONTROL CABLE ASSEMBLY

    1. C341125

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

    2. C341126

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

  22. REMOVE NO. 1 CLUTCH HOUSING COVER

    1. C341128

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

  23. REMOVE NO. 2 MANIFOLD STAY

    1. C341129

      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 GROUND CABLE

    1. C341130

      Remove the bolt and disconnect the ground cable.

  25. DISCONNECT CLUTCH RELEASE CYLINDER ASSEMBLY

    1. C346604

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

  26. DISCONNECT WIRE HARNESS

    1. C341131

      Remove the 3 bolts and disconnect the 2 connectors.

  27. LOOSEN ENGINE AND TRANSAXLE CONNECTING BOLT

    1. C341132

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

    2. C341133

      Loosen the 4 bolts.

    3. C341134

      Loosen the through bolt.

  28. REMOVE FRONT SUSPENSION MEMBER

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  29. SUPPORT MANUAL TRANSAXLE ASSEMBLY

    1. Support the manual transaxle assembly with a transmission jack and tie down band so that it is stable.

  30. REMOVE FRONT CROSSMEMBER SUB-ASSEMBLY

    1. C341135

      Remove the 6 bolts and front crossmember sub-assembly.

  31. REMOVE FRONT ENGINE MOUNTING INSULATOR

    1. C341136

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

  32. REMOVE MANUAL TRANSAXLE ASSEMBLY

    Note:

    • As there is very little space around the manual transaxle assembly, be extremely careful that the body, clutch pipe line and radiator cooling fan do not interfere with the manual transaxle assembly 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 step.

    1. C341137

      Remove the nut and through bolt, and then disconnect the engine mounting insulator LH from the engine mounting bracket LH.

    2. Lower the transmission jack a little at a time. 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. C341138

      Remove the 4 bolts and engine mounting insulator LH.

    4. C341139

      Remove the 4 bolts and engine mounting bracket LH.

      Note:

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

    5. C341140

      Use a cloth, etc. to protect the clutch pipe line in the area indicated in the illustration.

    6. C341141C01

      *1

      Crankshaft Damper Sub-assembly

      *2

      Body

      Lower the transmission jack a little at a time. Slightly tilt the engine assembly and manual transaxle assembly.

      Note:

      Be careful that the body and crankshaft damper sub-assembly do not interfere with each other.

    7. C341142C01

      *a

      Engine Support Point

      Support the engine assembly with an engine lifter as shown in the illustration so that it is stable.

    8. C341143

      Remove the 6 bolts shown in the illustration.

    9. While making sure that the clutch pipe line does not interfere with the manual transaxle assembly, slowly disconnect the manual transaxle assembly from the engine assembly until the input shaft is clear of the diaphragm spring of the clutch cover.

    10. Slowly lower the transmission jack and remove the manual transaxle assembly.

  33. REMOVE REAR ENGINE MOUNTING INSULATOR

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  34. REMOVE FRONT ENGINE MOUNTING BRACKET

    1. C341144

      Remove the 4 bolts and front engine mounting bracket.

  35. REMOVE REAR ENGINE MOUNTING BRACKET

    1. C341145

      Remove the 5 bolts and rear engine mounting bracket.