Manual Transaxle Removal and Installation

REMOVAL

WARNING:
- Make sure jacks and safety stands are placed properly.
- Apply parking brake and block rear wheels so the vehicle will not roll off stands and fall on you while working under it.

CAUTION: Use fender covers to avoid damaging painted surfaces.

NOTE: The original radio has a coded theft protection circuit. Be sure to get the customer's code number before
- disconnecting the battery.
- removing the No. 39 (7.5 A) fuse from the underhood fuse/relay box.
- removing the radio.

After service, reconnect power to the radio and turn it on. When the word "CODE" is displayed, enter the customer's 5-digit code to restore radio operation.

1. Disconnect the negative H cable first, then the positive W cable from the battery. Remove the battery from the battery tray.
2. Drain the transmission fluid.
3. Remove the battery tray and tray bracket.
4. Remove the intake air duct and air cleaner housing assembly.
5. Disconnect the connector and vacuum hoses, then remove the intake air resonator.
6. Disconnect the starter motor cables, then remove the starter motor.

NOTE: When installing the starter motor cable, make sure that the crimped side of the ring terminal is facing out.

7. Disconnect the back-up light switch connectors.





8. Remove the transmission ground cable and starter motor cable clamp.





9. Disconnect the vehicle speed sensor (VSS) connector.





10. Remove the wire harness clamp.
11. Shift the transmission into reverse.





12. First remove the cable bracket, then disconnect the cables from the top of the transmission housing. Remove both cables and the bracket together. Take care not to bend the cables.





13. Remove the clutch damper bracket mounting bolts, and raise the clutch damper bracket. Take care not to bend the clutch lines.





14. Remove the slave cylinder, clutch line, and clutch hose joint. Do not operate the clutch pedal once the slave cylinder has been removed. Take care not to bend the clutch line.

NOTE: Use only Super High Temp Urea Grease (P/N 08798-9002).





15. Remove the two upper transmission mounting bolts.





16. Remove the engine splash shield.





17. Remove the cotter pins and loosen the castle nuts, then separate the ball joints and lower arms on both sides.
18. Remove the right damper fork bolt.





19. Remove the right radius rod.

NOTE: Check for deterioration or damage of the radius rod rubber bushings. Replace them if necessary.





20. Remove the driveshafts and intermediate shaft . Coat all precision finished surfaces with clean engine oil or grease. Tie plastic bags over the driveshaft ends.





21. Swing the right driveshaft to the inner fender.





22. Remove the center beam.





23. Remove the engine stiffener.





24. Remove the intake manifold bracket.





25. Remove the three rear mount bracket mounting bolts.
26. Place a floor jack under the transmission, and raise the transmission just enough to take weight off of the mounts.





27. Remove the transmission mount and the transmission mount bracket.





28. Remove the three lower transmission mounting bolts.
29. Pull the transmission away from the engine until it clears the mainshaft.

CAUTION: Take care not to bend the clutch lines.

INSTALLATION
Install the transmission assembly in the reverse order of removal.
- Before installing, check that the two dowel pins are installed in the clutch housing.
- Apply grease to the release fork and release bearing.





- Torque the mounting bolts and nuts in the sequence shown.
- Make sure the bushings are not twisted or offset.





- Turn the boot of the shift lever so the hole is facing down.
- Inspect the plastic washer for wear and damage.
- Use only Super High Temp Urea Grease (P/N 08798 - 9602).
- Check that the new cotter pin is seated firmly.





- Loosen the three mounting bolts of the front engine mount/bracket, then torque the three mount bolts. Make sure the motor mount bushing is not twisted or offset. If the motor mount bushing is twisted or offset, loosen all mounts and retorque. Refer to section 5 for engine mount torque sequence.





- Turn the breather cap so that the "F" mark points at the front of the vehicle as shown.
- Refill the transmission with the recommended fluid.
- Connect the positive (+) cable first, then the negative H cable to the battery.
- Check the clutch operation.
- Shift the transmission and check for smooth operation.
- Check the front wheel alignment.