Manual Transmission/Transaxle: Service and Repair
Prior to any operation that requires removal of the actuator, the master cylinder pushrod must be disconnected from the clutch pedal. Failure to disconnect pushrod will result in permanent damage to the actuator if the clutch pedal is depressed without resistance from clutch loads. Master cylinder push rod bushing must also be replaced whenever it has been removed from the clutch pedal.1. Disconnect battery ground cable.
2. Install engine support fixture tool No. J-28467-A or equivalent, together with support leg tool No. J-36462 or equivalent.
3. Remove air cleaner housing and air intake tube.
4. Remove clutch actuator from transaxle. Refer to procedure outlined under "Clutch Actuator, Replace." Refer to "Clutch Actuator, Replace."
5. Disconnect electrical connector at speedometer driven gear sensor.
6. Remove nut and retaining clamp securing shift and select cables to transaxle.
7. Remove two nuts from cable ball stud at transaxle levers.
8. Disconnect exhaust crossover pipe at left exhaust manifold.
9. Disconnect EGR tube from crossover pipe.
10. Remove crossover to exhaust pipe connecting bolts.
11. Loosen crossover to right exhaust manifold clamp.
12. Swing crossover upward to gain access to top transaxle bolts.
13. Remove two upper trans axle mounting bolts and two upper transaxle mounting studs, leaving one lower mounting bolt and one lower mounting stud attached.
14. Disconnect electrical connector at back-up lamp switch.
15. Raise and support vehicle, then remove drain plug to drain transaxle fluid.
16. Remove four clutch housing cover retaining screws.
17. Remove both front tire and wheel assemblies, then the left and right wheelhouse splash shields.
18. Disconnect power steering cooler lines from frame, then remove power steering rack and pinion heat shield.
19. Disconnect power steering rack and pinion at frame.
20. Disconnect ball joints at steering knuckle.
21. Remove transaxle mount upper retaining bolts, then the engine mount lower retaining nuts.
22. Remove subframe retaining bolts from body, then remove subframe from vehicle.
23. Remove drive axles from transaxle and support from body.
24. Detach starter assembly and support from body.
25. Securely attach transaxle to suitable jack, then remove remaining transaxle mounting bolt and stud and remove transaxle.
26. Reverse procedure to install, noting the following:
a. Torque transaxle to engine attaching bolts and studs to 55 ft. lbs.
b. Using frame or lower control arm for leverage, seat drive axle into transaxle, using screwdriver/pry bar at groove provided on inner joint.
c. Verify that axle snap ring is seated by tapping on inner groove with screwdriver. Also, grasp inner housing and pull outboard. Do not pull on axle shaft. If snap ring is seated, axle will remain in place.
d. After positioning frame with body mount bolts installed but not tightened, align frame to body by inserting two 19 mm (0.74 inch) diameter by 203 mm (8 inch) long pins in alignment holes on right side of frame, then Torque body mount bolts to 100 ft. lbs. Alignment pins must not be removed until all body mount bolts are tightened to specifications. Alignment pins must be kept perpendicular to frame. Right side body mounts (nearest alignment pins) should be tightened first to maintain correct front wheel alignment.
e. Torque clutch housing cover retaining screws to 115 in. lbs.