Manual Transmission/Transaxle: Service and Repair

1. Wedge a block of wood approximately seven inches long under clutch pedal.
2. Disconnect battery ground cable, then raise and support vehicle.
3. Remove catalytic converter inlet pipe to turbocharger attaching nuts.
4. Remove attaching nuts at catalytic converter outlet to muffler inlet flange and the catalytic converter support bracket.
5. Remove catalytic converter and inlet pipe as an assembly.
6. Remove driveshaft, installing suitable plug in extension housing seal.
7. Remove starter, then the front stabilizer bar to body U-brackets and the body stiffener rod.
8. Position block of wood between stabilizer bar and body side rail.
9. Support transmission with suitable jack and remove bolt attaching rear mount to transmission.
10. Remove bolts attaching rear mount to body and remove mount, then loosen engine mount attaching nuts until only two or three threads are visible on end of stud.
11. Position block of wood against engine oil pan and raise front of engine with suitable stand. Raise engine until stud nuts on engine mounts contact the crossmember and, as engine tilts downward, lower jack supporting transmission.
12. Disconnect electrical connectors at back-up light switch and neutral safety switch.
13. Remove attaching bolts and raise transmission shift lever out of extension housing.
14. Remove snap ring and pull speedometer cable out of extension housing.
15. Remove clutch release lever cover, then pull rearward on clutch release cable and disengage from release lever.
16. Remove attaching screws from speedometer cable routing clips and position cable out of way on left side of vehicle.
17. Remove bolt attaching engine rear cover plate to flywheel housing.
18. Remove flywheel housing attaching bolts located at top of housing, then the four remaining flywheel housing attaching bolts.
19. Pull transmission rearward until flywheel housing contacts body.
20. Raise rear of transmission and pull rearward to clear body, then lower rear of transmission and pull rearward to remove.
21. Reverse procedure to install, noting the following:
a. Torque flywheel housing attaching bolts to 28-38 ft. lbs.
b. Torque engine rear cover attaching bolt to 28-38 ft. lbs.
c. Torque engine mount stud nuts to 50-70 ft. lbs.
d. Torque rear mount to body attaching bolts to 25-35 ft. lbs.
e. Torque rear mount to transmission attaching bolt to 50-70 ft. lbs.
f. Torque U-bracket and body stiffener rod attaching bolts to 33-41 ft. lbs.
g. Torque attaching nuts to 21-30 ft. lbs. at converter outlet and 25-35 ft. lbs. at turbocharger.
22. After installation is completed, press clutch pedal to floor several times to adjust clutch cable freeplay.