Manual Transmission/Transaxle: Service and Repair

1. Disconnect battery ground cable.
2. Remove three starter attaching bolts.
3. Disconnect clutch cable from fork and remove housing stop.
4. Place T.Av. 509-01 support spacers or equivalent between lower shock absorber attaching pins and lower suspension arm shafts.
5. Loosen lug nuts on front wheels.
6. Raise and support vehicle, ensuring that spacers remain in place.
7. Remove front wheels.
8. Remove brake calipers.
9. Using pin drift B.Vi. 31-01 or equivalent, punch out drive shaft roll pins on side gear shafts.
10. Remove steering tie rod ball joint nut.
11. Using ball joint puller T.Av. 476 or equivalent as necessary, loosen steering ball joint cone.
12. Disengage drive shaft from side gear shaft by tilting stub axle carrier.
13. Proceed in same manner for other side.
14. Disconnect speedometer cable, gearshift linkage, and electrical connectors for back-up lights and emission control switches.
15. Remove clutch cover.
16. Install suitable jack under transaxle, then remove transaxle mounts.
17. Remove engine to transaxle attaching bolts.
18. Pull transaxle toward rear of vehicle, being careful not to catch it on pressure plate.
19. Using suitable lubricant, lightly lubricate clutch splines.
20. Engage transaxle, being careful not to catch clutch mechanism.
21. Mount engine and transaxle, then attach transaxle mounts.
22. Remove jack.
23. Install clutch cover, ensuring it is clear of TDC sensor, if equipped.
24. Reconnect speedometer cable, gearshift lever, and electrical connectors for back-up lights and emission control switches.
25. Using suitable lubricant, lightly lubricate differential side gear splines.
26. Position drive shaft next to side gear.
27. Engage drive shaft in side gear by tilting stub axle carrier. Use elbow pin drift B.Vi. 31-01 or equivalent to line up holes, if necessary.
28. Engage stub axle carrier in upper suspension ball joint.
29. Using suitable tool, lock cone and torque nut to 48 ft.lbs.
30. Engage steering tie rod ball joint, then, using suitable tool, lock cone and torque nut to 29 ft.lbs.
31. Install front brake calipers.
32. Proceed in same manner for other side.
33. Install front wheels and lower vehicle to ground, then torque lug nuts to 59 ft.lbs.
34. Remove spacers.
35. Connect clutch cable to fork.
36. Place starter in housing, then pull support bracket into line and tighten bolt.
37. Tighten starter bolts and reconnect wires.
38. Adjust gearshift lever and clutch clearance.
39. Connect battery ground cable.