Manual Transmission/Transaxle: Service and Repair

Transmission Replacement

Removal Procedure

1. Remove battery tray. Refer to Battery Tray Replacement Service and Repair.

2. Remove the transmission shift lever cable from transmission. Refer to Manual Transmission Shift Lever and Selector Lever Cable Replacement Manual Transmission Shift Lever and Selector Lever Cable Replacement.




3. Disconnect the electrical connector (1) from the backup lamp switch.





Note: Before disconnecting the clutch actuator cylinder front pipe, remove the clutch/brake fluid from the reservoir tank.

4. Remove the clutch actuator cylinder front pipe retainer (1).

5. Disconnect the clutch actuator cylinder front pipe (2) from the clutch actuator cylinder pipe elbow.




6. Unclip the wire harness from the transmission.

7. Remove the 3 upper transmission bolts from engine (1).

8. Remove the drivetrain and front suspension frame. Refer to Drivetrain and Front Suspension Frame Replacement .




9. Remove transmission front mount from transmission (2). Remove 2 bolts (1).




10. Remove the transmission mount bracket bolts (1) and the rear transmission mount bracket (2).

11. Drain transmission fluid.

12. Disconnect the left front wheel drive shaft from the transmission. Refer to Front Wheel Drive Shaft Replacement - Left Side Front Wheel Drive Shaft Replacement - Left Side.

13. Disconnect the right front wheel drive shaft from the transmission. Refer to Front Wheel Drive Shaft Replacement - Right Side Front Wheel Drive Shaft Replacement - Right Side.

14. Lower the vehicle.




15. Remove and DISCARD the transmission mount bolts (1) from transmission mount bracket.

16. Lower the engine and the transmission on the left hand side with the engine support fixture.




17. Remove transmission mount bracket - left side from transmission (2). Remove 3 transmission mount bracket bolts (1).

18. Raise the vehicle.




19. Using a suitable straps or chains, secure the transmission to a suitable transmission jack.

20. Remove 4 transmission lower bolts (1)

21. Remove transmission lower bolt and nut (2)

Caution: Refer to Fastener Caution Fastener Caution.

22. Install NEW oil drain plug and tighten to 20 Nm (15 lb ft).




23. Remove the remaining lower transmission bolts (1).

24. Separate the transmission from the engine.

25. Lower the transmission from the vehicle.

Installation Procedure

Warning

Use care when cleaning the clutch hub. The clutch hub may have sharp edges and can cause personal injury if contact is made. Wear protective gloves to avoid personal injury.

1. Clean the clutch hub and the input shaft from any debris and contaminates with a lint-free towel.





Caution:
Applying too much or the wrong type of grease on the transmission input shaft may cause damage, clutch slippage or failure. Always apply the correct type of grease. Never apply more grease than is necessary to coat the transmission input shaft with a very thin film of grease.

2. Use a clean flat brush (1) to apply very light coating of multi-purpose grease to input shaft until the metal is only shiny. No visible clumps of grease are permissible regardless of size. Smear away from the transmission in direction of the shown arrow.





Caution:
Ensure that no grease remains on the lead surface of the transmission input shaft. Clean the lead surface of the transmission input shaft prior to the assembly of the transmission to the engine. Failure to maintain a clean surface may cause clutch slippage or failure.

3. Clean the entire lead surface of the input shaft with a NEW, lint-free towel (1).

4. Raise the transmission with the transmission jack and position the transmission to the engine.





Caution: Refer to Fastener Caution Fastener Caution.

5. Install transmission lower bolt (1) and tighten to 60 Nm (44 lb ft).

6. Remove the transmission jack.




7. Install 3 transmission lower bolts (1) and tighten to 40 Nm (32 lb ft).

8. Install transmission bolt (3) and tighten to 60 Nm (44 lb ft).

9. Install transmission lower bolt and nut (2) and tighten to 40 Nm (32 lb ft).

10. Lower the vehicle.




11. Install transmission mount bracket - left side. Install 3 transmission mount bracket bolts (1) and tighten to 100 Nm (74 lb ft).

12. Raise the engine and the transmission on the left hand side with the engine support fixture.




13. Install the 3 NEW transmission mount bolts (1) but do not tighten yet.

14. Raise the vehicle.

15. Install the front wheel drive intermediate shaft. Refer to Front Wheel Drive Intermediate Shaft Replacement Front Wheel Drive Intermediate Shaft Replacement.

16. Install the left front wheel drive shaft to the transmission. Refer to Front Wheel Drive Shaft Replacement - Left Side Front Wheel Drive Shaft Replacement - Left Side.




17. Install the transmission mount bracket - rear (2) and tighten the bolts (1) to 100 Nm (74 lb ft).




18. Install transmission front mount to transmission (2). Install 2 transmission front mount bolts (1) and tighten to 100 Nm (74 lb ft).

19. Install the drivetrain and front suspension frame. Refer to Drivetrain and Front Suspension Frame Replacement .

20. Lower the vehicle.





Caution: Refer to Torque-to-Yield Fastener Caution Torque-to-Yield Fastener Caution.

21. Tighten the transmission mount bolts left side (1) to 50 Nm (46 lb ft) plus 60-75 degrees.

22. Remove the engine support fixture.




23. Install the upper transmission bolts (1) to engine and tighten to 60 Nm (44 lb ft).




24. Connect the clutch actuator cylinder front pipe (2) to the clutch actuator cylinder pipe elbow.

25. Install the clutch actuator cylinder front pipe retainer (1) to the clutch actuator cylinder pipe elbow.




26. Connect the electrical connector (1) to the backup lamp switch.

27. Install the transmission shift lever cable to transmission. Refer to Manual Transmission Shift Lever and Selector Lever Cable Replacement Manual Transmission Shift Lever and Selector Lever Cable Replacement.

28. Adjust the shift lever and selector lever cables. Refer to Manual Transmission Shift Lever and Selector Lever Cable Adjustment Manual Transmission Shift Lever and Selector Lever Cable Adjustment.

29. Bleed the clutch hydraulic system. Refer to Hydraulic Clutch System Bleeding Service and Repair.

30. Inspect the transmission fluid level.

31. Install the battery tray. Refer to Battery Tray Replacement Service and Repair.

32. Road test the vehicle.