Transmission Replacement

MANUAL TRANSAXLE ASSY (MTM)
REPLACEMENT
1. REMOVE FRONT WHEELS
2. REMOVE ENGINE UNDER COVER LH
3. REMOVE ENGINE UNDER COVER RH
4. DRAIN TRANSAXLE OIL
a. Remove the filler plug and the gasket.
b. Remove the drain plug, the gasket and the manual transaxle oil.
c. Install a new gasket and the drain plug.
Torque: 39 Nm (400 kgf-cm, 29 ft. lbs.)
5. REMOVE HOOD SUB-ASSY
6. REMOVE COWL PANEL SUB-ASSY
7. REMOVE CYLINDER HEAD COVER NO.2
8. REMOVE AIR CLEANER ASSY
9. REMOVE BATTERY





10. DISCONNECT WIRE HARNESS
a. Remove the bolt and disconnect the wire harness clamp.
11. DISCONNECT CONNECTOR
a. Disconnect the back-up lamp switch connector.





12. DISCONNECT CLUTCH RELEASE CYLINDER TO FLEXIBLE HOSE TUBE
a. Using SST, disconnect the flexible hose tube.
SST 09023-00100

HINT: Use a container to catch the fluid.

b. Remove the 2 bolts and separate the flexible hose tube.





13. REMOVE AIR CLEANER BRACKET
a. Remove the bolt and the air cleaner bracket.





14. DISCONNECT TRANSMISSION CONTROL CABLE ASSY
a. Remove the 2 clips and the 2 washers, and disconnect the 2 cables from the transaxle.
b. Remove the 2 clips, and disconnect the 2 cables from the control cable bracket.
15. REMOVE FRONT DRIVE SHAFT ASSY LH
SST 09520-01010, 09520-24010 (09520-32040)
16. REMOVE FRONT DRIVE SHAFT ASSY RH
17. REMOVE FLOOR PANEL BRACE FRONT
18. REMOVE EXHAUST PIPE ASSY FRONT





19. SUSPEND ENGINE ASSY
a. Install the 2 hangers in the correct direction.
b. Attach the engine chain hoist to the hangers.

CAUTION: Do not attempt to hang the engine by hooking the chain to any other part.

Parts No.:
Engine Hanger: 12281-21010
Bolt: 91642-81025
Torque: 40 Nm (408 kgf-cm, 29 ft. lbs.)
20. REMOVE FRONT SUSPENSION CROSSMEMBER SUB-ASSY





21. REMOVE STARTER ASSY
a. Remove the flywheel housing side cover.
b. Remove the nut and disconnect the starter wire.
c. Disconnect the connector.
d. Remove the 2 bolts and the starter assy.
22. SUPPORT MANUAL TRANSAXLE ASSY
a. Support the manual transaxle with a transmission jack.





23. REMOVE ENGINE MOUNTING BRACKET LH
a. Remove the bolt, and disconnect the ground cable.





b. Remove the 2 bolts, and separate the engine mounting bracket LH from the engine mounting insulator LH.
c. Remove the 3 bolts and the engine mounting bracket LH from the manual transaxle.





24. REMOVE ENGINE MOUNTING BRACKET RR
a. Remove the 4 bolts and the engine mounting bracket RR from the manual transaxle.





25. REMOVE MANUAL TRANSAXLE ASSY
a. Remove the 7 bolts and the manual transaxle from the engine.





26. INSTALL MANUAL TRANSAXLE ASSY
a. Align the input shaft with the clutch disc and install the manual transaxle on the engine.
b. Install the 7 bolts.
Torque: 33 Nm (340 kgf-cm, 24 ft. lbs.)





27. INSTALL ENGINE MOUNTING BRACKET RR
a. Install the engine mounting bracket RR and the 4 bolts on the manual transaxle.
Bolt A:
Torque: 49 Nm (500 kgf-cm, 36 ft. lbs.)
Bolt B:
Torque: 18 Nm (180 kgf-cm, 13 ft. lbs.)





28. INSTALL ENGINE MOUNTING BRACKET LH
a. Install the engine mounting bracket LH on the manual transaxle with the 3 bolts.
Torque: 64 Nm (653 kgf-cm, 47 ft. lbs.)
b. Install the engine mounting bracket LH on the engine mounting insulator with the 2 bolts.
Torque: 49 Nm (500 kgf-cm, 36 ft. lbs.)





c. Install the ground cable on the engine mounting bracket with the bolt.
Torque: 26 Nm (260 kgf-cm, 19 ft. lbs.)





29. INSTALL STARTER ASSY
a. Install the starter assy and the 2 bolts on the manual transaxle.
Torque: 37 Nm (380 kgf-cm, 27 ft. lbs.)
b. Connect the starter connector.
c. Install the wire and the nut on starter assy.
Torque: 9.8 Nm (100 kgf-cm, 87 in. lbs.)
d. Install the flywheel housing side cover.
30. INSTALL FRONT SUSPENSION CROSSMEMBER SUB-ASSY
SST 09670-00010
31. INSTALL FRONT DRIVE SHAFT ASSY LH
32. INSTALL FRONT DRIVE SHAFT ASSY RH

HINT: Install the RH side by the same procedures as the LH side.

33. INSTALL FRONT AXLE ASSY LH
34. INSTALL FRONT AXLE ASSY RH

HINT: Install the RH side by the same procedures as the LH side.

35. INSTALL EXHAUST PIPE ASSY FRONT
36. INSTALL FLOOR PANEL BRACE FRONT





37. CONNECT TRANSMISSION CONTROL CABLE ASSY
a. Connect the 2 cable ends, and install the 2 washers and the 2 clips.
b. Install 2 new clips on the control cable bracket.





38. INSTALL AIR CLEANER BRACKET
a. Install the air cleaner bracket with the bolt.
Torque: 19 Nm (195 kgf-cm, 14 ft. lbs.)





39. CONNECT CLUTCH RELEASE CYLINDER TO FLEXIBLE HOSE TUBE
a. Using SST, connect the flexible hose tube.
SST 09020-00100
Torque: 15 Nm (155 kgf-cm, 11 ft. lbs.)
b. Connect the flexible hose tube with the 2 bolts.
Torque: 19 Nm (195 kgf-cm, 14 ft. lbs.)
40. CONNECT CONNECTOR
a. Connect the back-up lamp switch connector.





41. CONNECT WIRE HARNESS
a. Connect the wire harness clamp with the bolt.
Torque: 5.0 Nm (51 kgf-cm, 44 in. lbs.)
42. INSTALL BATTERY
43. INSTALL AIR CLEANER ASSY
44. INSTALL CYLINDER HEAD COVER NO.2
Torque: 7.0 Nm (71 kgf-cm, 62 in. lbs.)
45. INSTALL COWL PANEL SUB-ASSY
46. INSTALL HOOD SUB-ASSY
47. INSPECT HOOD SUB-ASSY
48. ADJUST HOOD SUB-ASSY
49. INSTALL FRONT WHEELS
Torque: 103 Nm (1,050 kgf-cm, 76 ft. lbs.)
50. ADD TRANSAXLE OIL
51. INSPECT AND ADJUST TRANSAXLE OIL
52. INSTALL ENGINE UNDER COVER RH
53. INSTALL ENGINE UNDER COVER LH
54. INSPECT FRONT WHEEL ALIGNMENT
55. CHECK ABS SPEED SENSOR SIGNAL
56. CHECK FOR EXHAUST GAS LEAKS