Manual Transmission/Transaxle: Service and Repair

Description:

1. Disconnect battery ground cable, then remove air cleaner assembly.
2. Remove sound insulator from passenger compartment, then disconnect clutch master cylinder push rod from clutch pedal.
3. Disconnect hydraulic clutch slave cylinder and bracket from transaxle. Use caution not to allow manual clutch shaft to move while removing or installing clutch lever.
4. Remove exhaust crossover pipe, then disconnect shift cables at transaxle..
5. Install suitable engine support fixture, then remove top transaxle to engine attaching bolts.
6. Raise and support vehicle, then install suitable drive axle boot seal protectors on both inner and outer seals.
7. Remove left front wheel assembly, and then lower vehicle.
8. Remove left side frame and crossmember assembly as follows:

a. Install necessary engine support fixtures.
b. Disconnect intermediate shaft assembly from rack and pinion gear stub shaft. Position attaching bolt in up position before removal.
c. Raise and support vehicle, then remove power steering line brackets.
d. Remove steering gear mounting bolts. Position steering aside.
e. Disconnect front stabilizer bar from left lower control arm, then left lower ball joint at knuckle.
f. Remove both front stabilizer bar reinforcements and bushings from right and left side members.
g. Using a 1/2 inch drill, drill through spotweld located between rear holes of left front stabilizer bar mounting, see figure.
h. Remove engine and transaxle mounts from frame, then side to crossmember bolts, see figure.
i. Remove bolts from left frame mounts, then left side and front crossmember assembly. If necessary gently pry crossmember loose.
9. Drain transaxle, then disengage lefthand drive axle from transaxle.
10. Remove clutch housing cover bolts,then speedometer cable.
11. Attach suitable jack to transaxle case, the remove remaining transaxle to engine bolts.
12. Slide transaxle away from engine. Carefully lower jack guiding righthand drive axle out of transaxle.
13. Reverse procedure to install, noting the following:

a. When installing transaxle, position right side drive axle shaft into its bore, as driveshaft cannot be installed after transaxle is attached to engine.
b. After transaxle is attached to engine and lefthand drive axle shaft is installed, immediately install frame and attaching bolts.