Manual Transmission/Transaxle: Service and Repair

1. Disconnect battery ground cable.
2. On vehicles with diesel engine, remove air cleaner assembly.
3. On all vehicles, remove windshield washer reservoir.
4. Remove upper engine to transmission attaching bolts.
5. Disconnect speedometer cable, then remove spring clip from clutch slave cylinder.

Fig. 1 Removing clutch slave cylinder lock pin:

6. Drive out lock pin for clutch slave cylinder, Fig. 1, then remove clutch slave cylinder, leaving lines attached.

Fig. 2 Engine support tool No. 10-222:

7. Attach tool No. 10-222 or equivalent and support engine, Fig. 2.
8. On vehicles with diesel engine, remove splash shield from beneath engine and transmission.
9. On all vehicles, remove front exhaust pipe.
10. Remove right side guard plate, then disconnect driveshafts at flanges and rest driveshafts on top of subframe.
11. Disconnect electrical connectors from back-up light switch.
12. Pry off shift and adjusting rods.
13. Remove lower engine to transmission attaching bolts, then the starter.
14. Remove guard plate from subframe.
15. Install tools US618/1 or equivalents on suitable jack and lift transmission slightly.
16. Remove both rear subframe attaching bolts.
17. Remove both transmission support bolts from subframe.
18. Remove right side transmission bracket.
19. Pull transmission off dowel sleeves, then lower transmission and remove from under vehicle.
20. Reverse procedure to install, noting the following:
a. Coat mainshaft splines with suitable lubricant.
b. Install transmission on engine dowels and install lower engine to transmission attaching bolts.
c. Check gear shift adjustments.
d. Torque bracket to transmission attaching bolts and transmission support to subframe mounting bolts to 29 ft.lbs.
e. Torque driveshaft to flange attaching bolts to 33 ft.lbs.
f. Torque transmission to engine mounting bolts to 40 ft.lbs.
g. Torque subframe to body attaching bolts to 80 ft.lbs.