Removal and Installation

Part 1:

Part 2:

Removal and installation the parts as shown.

TRANSAXLE REMOVAL




1. REMOVE NEGATIVE BATTERY CABLE
2. REMOVE AIR CLEANER CASE ASSEMBLY WITH AIR HOSE
3. REMOVE CRUISE CONTROL ACTUATOR
a. Remove the cruise control actuator cover.
b. Disconnect the connector.
c. Remove the three bolts and cruise control actuator with bracket.




4. REMOVE CLUTCH RELEASE CYLINDER




5. REMOVE STARTER
a. Disconnect the connector and wire from the starter.
b. Remove the two bolts and starter.




6. REMOVE CLUTCH ACCUMULATOR AND TUBE CLAMP
a. Remove the two bolts and clutch accumulator with bracket.
b. Remove the bolt and clutch tube clamp.




7. DISCONNECT BACK - UP LIGHT SWITCH CONNECTOR




8. DISCONNECT WIRES CLAMPS




9. REMOVE CLUTCH RELEASE CYLINDER BRACKET




10. REMOVE EARTH CABLES




11. DISCONNECT CONTROL CABLES
a. Remove the clips and washers.
b. Remove the retainer from the cables.




12. REMOVE TRANSAXLE MOUNTING THREE BOLTS OF TRANSAXLE CASE UPPER SIDE





13. DISCONNECT SPEED SENSOR CONNECTOR




14. REMOVE FRONT WHEEL
15. RAISE VEHICLE

NOTE: Be sure the vehicle is securely supported.

16. REMOVE UNDER COVERS AND SIDE COVERS
17. DRAIN TRANSAXLE OIL
18. REMOVE EXHAUST FRONT PIPE
a. Remove the four nuts.




b. Remove the two bolts and front pipe support.




d. Remove the two bolts and nuts.
e. Remove the front pipe.




19. REMOVE DRIVE SHAFT Service and Repair







20. DISCONNECT STEERING GEAR HOUSING FROM FRONT SUSPENSION MEMBER
a. Remove the four bolts.
b. Remove the stabilizer bar bushing bracket.




c. Remove the two set bolts and nuts.
d. Disconnect the steeling gear housing from the front suspension member.

HINT: Suspend the steering gear housing with cord.




21. REMOVE STIFFENER PLATE




22. REMOVE ENGINE ABSORBER
Remove the four bolts and engine absorber.




23. REMOVE ENGINE FRONT MOUNTING SET BOLTS AND NUT
Remove the two bolts and a nut.




24. REMOVE ENGINE REAR MOUNTING SET NUTS
a. Remove the two hole plugs.
b. Remove the four nuts.




25. REMOVE ENGINE LEFT MOUNTING
a. Raise the transaxle and engine slightly with a jack and wooden block in between.
b. Remove the two hole plugs and nuts.




c. Remove the three bolts and engine left mounting.




26. REMOVE STEERING COOLER PIPE SET BOLTS




27. REMOVE FRONT SUSPENSION MEMBER
a. Remove the left and right fender liner set screws.




b. Remove the two bolts and four nuts.




c. Remove the four bolts.
d. Remove the two front lower braces, rear lower braces and front suspension member.




28. REMOVE TRANSAXLE
a. Remove the transaxle mounting bolts from the engine.
b. Lower the engine left side and remove the transaxle from the engine.

TRANSAXLE INSTALLATION




1. INSTALL TRANSAXLE TO ENGINE
a. Align the input shaft spline with the clutch disc and install the transaxle to the engine.
b. Torque the bolts.

Bolt A
Torque: 64 N.m (650 kgf-cm, 47 ft-lbf)
Bolt B
Torque: 46 N.m (470 kgf-cm, 34 ft-lbf)




2. INSTALL FRONT SUSPENSION MEMBER
a. Install the front suspension member, rear lower brace, front lower brace and four bolts.
b. Torque the four bolts.

Torque: 181 N.m (1,850 kgf-cm, 134 ft-lbf)




c. Install and torque the two bolts and four nuts.

Bolt
Torque: 32 N.m (330 kgf-cm, 24 ft-lbf)
Nut
Torque: 36 N.m (370 kgf-cm, 27 ft-lbf)




d. Install the left and right fender liner set screws.




3. INSTALL STEERING COOLER PIPE SET BOLTS




4. INSTALL ENGINE LEFT MOUNTING
a. Install the engine left mounting.
b. Install and torque the three bolts.

Torque: 64 N.m (650 kgf-cm, 47 ft-lbf)




b. Install and torque the two nuts.

Torque: 80 N.m (820 kgf-cm, 59 ft-lbf)

c. Install the two hole plugs.




5. INSTALL ENGINE REAR MOUNTING SET NUTS
a. Install and torque the four nuts.

Torque: 80 N.m (820 kgf-cm, 59 ft-lbf)

b. Install the two hole plugs.




6. INSTALL ENGINE FRONT MOUNTING SET BOLTS AND NUT
Install and torque the two bolts and a nut.

Torque: 80 N.m (820 kgf-cm, 59 ft-lbf)




7. INSTALL ENGINE ABSORBER
Install and torque the four bolts.

Torque: 48 N.m (490 kgf-cm, 35 ft-lbf)




8. INSTALL STIFFENER PLATE
Bolt A
Torque: 18 N.m (185 kgf-cm, 13 ft-lbf)
Bolt B
Torque: 37 N.m (380 kgf-cm, 27 ft-lbf)




9. CONNECT STEERING GEAR HOUSING TO FRONT SUSPENSION MEMBER
a. Connect the steering gear housing to the front suspension member.
b. Install and torque the two set bolts and nuts.

Torque: 181 N.m (1.850 kgf-cm, 134 ft-lbf)




c. Install the stabilizer bar bushing bracket.
d. Install and torque the four bolts.

Torque: 19 N.m (195 kgf-cm, 14 ft-lbf)




10. INSTALL DRIVE SHAFT Service and Repair




11. INSTALL EXHAUST FRONT PIPE
a. Install a new gasket.
b. Install the exhaust front pipe.
c. Install and torque the two bolt and new nuts.

Torque: 43 N.m (440 kgf-cm, 32 ft-lbf)




d. Install the exhaust front pipe support and two bolts.




e. Install two new gaskets.
f. Install and torque four new nuts.

Torque: 62 N.m (630 kgf-cm, 46 ft-lbf)




12. FILL TRANSAXLE WITH GEAR OIL
Oil:
Gear oil super (08885-02106) or equivalent Recommended oil
Oil grade:
API GL-4 or GL-5
Viscosity:
SAE 75W-90 or 80W-90
Above -18°C (0°F) SAE 90
Below -18°C (0°F) SAE 80W
Capacity:
4.2 Litters (4.4 US qts, 3.7 Imp. qts)

13. INSTALL UNDER COVERS AND SIDE COVERS
14. INSTALL FRONT WHEEL AND LOWER VEHICLE

Torque: 103 N.m (1.050 kgf-cm, 76 ft-lbf)

15. CONNECT SPEEDOMETER SENSOR CONNECTOR




16. CONNECT CONTROL CABLES
a. Install the retainer to the cables.
b. Connect the cables to the linkage with the washer and clips.




17. INSTALL EARTH CABLES




18. CONNECT WIRES CLAMPS




19. CONNECT BACK - UP LIGHT SWITCH CONNECTOR




20. INSTALL CLUTCH RELEASE CYLINDER BRACKET




21. INSTALL CLUTCH ACCUMULATOR AND TUBE CLAMP
a. Install the tube clamp and bolt.
b. Install and torque the two bolts.

Torque: 20 N.m (200 kgf-cm, 14 ft-lbf)




22. INSTALL STARTER
a. Install the starter.
b. Install and torque the two bolts.

Torque: 39 N.m (400 kgf-cm, 29 ft-lbf)

c. Connect the connector and wire to the starter.




23. INSTALL CLUTCH RELEASE CYLINDER AND TUBE CLAMP
a. Place the release cylinder and torque the two bolts.

Torque: 13 N.m (130 kgf-cm, 9 ft-lbf)

b. Install the tube clamp bolt.




24. INSTALL CRUISE CONTROL ACTUATOR
a. Install the cruise control actuator with bracket the three bolts.
b. Connect the connector.
c. Install the cruise control actuator cover.

25. INSTALL AIR CLEANER CASE ASSEMBLY WITH AIR HOSE
26. INSTALL NEGATIVE BATTERY CABLE
27. INSPECT FRONT WHEEL ALIGNMENT
28. PERFORM ROAD TEST
Check for abnormal noise and smooth shifting.