Manual Transmission/Transaxle: Service and Repair
MANUAL TRANSMISSION REMOVAL / INSTALLATIONRemoval
1. Remove the gearshift lever.
2. With the vehicle in neutral, position it on a hoist.
3. If transmission disassembly is required, drain the transmission fluid.
^ Install the drain plug after draining all the fluid.
^ Tighten to 48 Nm (4.9 kgf-m, 35 lb-ft).
Note:
^ To maintain initial propeller shaft balance, index mark the propeller shaft yoke to the axle flange, so they can be installed in their original positions.
4. Remove the rear propeller shaft.
5. On 4WD vehicles, remove the transfer case.
6. Disconnect the wire harness from the crossmember.
7. Position a suitable jack under the transmission. Secure the transmission to the jack with a safety strap.
8. Remove the 6 crossmember bolts.
9. Remove the 2 transmission mount nuts and the crossmember.
10. Remove the heated oxygen sensor (HO2S) bracket nut and the bracket from the extension housing.
11. Remove the 2 transmission mount bolts and the transmission mount.
12. For 4.0L engines, remove the catalytic converter Y-pipe.
13. Disconnect the vehicle speed sensor (VSS) electrical connector and the reverse lamp switch electrical connector. Then unclip the wiring harness from the transmission.
Caution:
^ Do not allow the starter to hang freely or damage to the wiring may occur.
14. Remove the 3 bolts from the starter motor. Using mechanic's wire, position the starter aside.
15. Using the special tool, disconnect the clutch hydraulic line.
16. Using a suitable jack, support the engine.
Note:
^ Lower the transmission enough to gain access to the upper transmission-to-engine bolts.
17. Remove the 9 transmission-to-engine bolts.
18. Pull the transmission rearward until the input shaft is clear of the pressure plate, then lower the transmission from the vehicle.
Installation
1. Apply a thin coat of grease on the input shaft splines.
Warning:
^ Secure the assembly to the jack. Avoid any obstructions while lowering and raising the jack. Contact with obstructions may cause the assembly to fall off the jack, which may result in serious personal injury.
2. Raise and position the transmission to the engine.
Note:
^ Before securing the engine to the transmission, connect the hydraulic line to the clutch slave cylinder.
3. Connect the clutch hydraulic line.
4. Install the 9 transmission-to-engine bolts.
^ Tighten to 55 Nm (5.6 kgf-m, 41 lb-ft).
5. Install the 3 bolts and the starter motor.
^ Tighten to 25 Nm (2.5 kgf-m, 18 lb-ft).
6. Connect the vehicle speed sensor (VSS) electrical connector and the reverse lamp switch electrical connector. Then clip the wiring harness to the transmission.
7. For 4.0L engines, install the catalytic converter Y-pipe.
8. Install the transmission mount and the 2 transmission mount bolts.
^ Tighten to 98 Nm (10 kgf-m, 72 lb-ft).
9. Install the heated oxygen sensor (HO2S) bracket and nut to the extension housing.
^ Tighten to 39 Nm (4.0 kgf-m, 29 lb-ft).
10. Install the crossmember and the 2 transmission mount nuts. Do not tighten the nuts at this time.
11. Install the 6 crossmember bolts.
^ Tighten the transmission mount nuts to 98 Nm (10 kgf-m, 72 lb-ft).
^ Tighten the crossmember bolts to 101 Nm (10.3 kgf-m, 74 lb-ft).
12. Remove the transmission jack.
13. Connect the wire harness to the crossmember.
14. On 4WD vehicles, install the transfer case.
15. Align the index marks made during removal and install the propeller shaft.
16. Install the upper gearshift lever and gearshift lever boot as an assembly.
17. Add specified amount of transmission oil.
18. Warm up the engine and transmission, inspect for oil leakage and inspect transmission operation.