Removal and Replacement
Manual Transmission AssemblyREMOVAL
1) Open the front hood fully, and support with stay.
2) Disconnect the battery ground terminal.
3) Remove the air intake duct and cleaner case.
MT Vehicles:
4) Remove the air cleaner case stay. (Non-turbo model)
5) Remove the intercooler (Turbo model)
6) Disconnect the following connectors.
1) Neutral position switch connector
2) Back-up light switch connector
^ Non-turbo model
^ Turbo model
3) Vehicle speed sensor
7) Remove the starter.
8) Remove the operating cylinder from the transmission.
^ Non-turbo model
^ Turbo model
9) Remove the pitching stopper.
10) Separate the clutch release fork from the release bearing. (Turbo model)
1) Remove the clutch operating cylinder from the transmission.
2) Remove the plug using 10 mm hexagon wrench.
3) Screw the 6 mm diameter bolt into the release fork shaft, and remove it.
4) Raise the release fork and unfasten the release bearing tabs to free release fork.
CAUTION: seep (4) is required to prevent interference with engine when removing engine from transmission.
11) Set ST.
NOTE: Also is available Part No. 927670000.
ST 41099AA020 ENGINE SUPPORT ASSY
12) Remove the bolt which holds right upper side of transmission to the engine.
13) Remove the front and center exhaust pipes. (Non-turbo model) with OBD
14) Remove the center exhaust pipe. (Turbo model).
15) Remove the rear exhaust pipe and muffler.
CAUTION: When removing exhaust pipes, be careful each exhaust pipe does not drop out.
16) Remove the heat shield cover. (If equipped)
17) Remove the hanger bracket from right side of transmission.
18) Remove the propeller shaft.
19) Remove the gear shift rod and stay from transmission.
1) Disconnect the stay from the transmission.
2) Disconnect the rod from the transmission.
20) Disconnect the stabilizer link from the transverse link.
21) Remove the bolt securing ball joint of transverse link to housing.
^ Except sedan turbo model
^ Sedan turbo model
22) Remove the spring pins and separate front drive shafts from each side of the transmission.
CAUTION: Discard removing spring pin. Replace with a new one.
23) Remove the nuts which hold lower side of transmission to the engine.
24) Place the transmission jack under transmission.
CAUTION: Always support transmission case with a transmission jack.
25) Remove the transmission rear crossmember from the vehicle.
26) Remove the transmission.
CAUTION: Move transmission jack toward rear until main shaft is withdrawn from clutch cover.
27) Separate the transmission assembly and rear cushion rubber.
INSTALLATION
1) Install the rear cushion rubber to the transmission assembly.
Tightening torque: 35 Nm (3.6 kgf-m, 26.3 ft. lbs.)
2) Install the clutch release lever and bearing onto the transmission. (Turbo model)
3) Install the transmission onto the engine.
1) Gradually raise the transmission with transmission jack.
2) Engage them at splines.
CAUTION: Be careful not to strike main shaft against clutch cover.
4) Install the transmission rear crossmember.
Tightening torque:
T1: 70 Nm (7.1 kgf-m, 51 ft. lbs.)
T2: 140 Nm (14.3 kgf-m, 103 ft. lbs.)
5) Take off the transmission jack.
6) Tighten the nuts which hold lower side of transmission to the engine.
Tightening torque: 50 Nm (5.1 kgf-m, 36.9 ft. lbs.)
7) Connect the engine and transmission.
1) Install the starter.
2) Tighten the bolt which holds right upper side of transmission to the engine.
Tightening torque: 50 Nm (5.1 kgf-m, 36.9 ft. lbs.)
8) Remove ST.
9) Push the clutch release lever to fit bearing into clutch cover.
10) Install the plug.
Tightening torque: 44 Nm (4.5 kgf-m, 32.5 ft. lbs.)
11) Install the pitching stopper.
Tightening torque:
T1: 50 Nm (5.1 kgf-m, 37 ft. lbs.)
T2: 58 Nm (5.9 kgf-m, 43 ft. lbs.)
12) Lift-up the vehicle.
13) Install the front drive shaft into the transmission.
14) Drive the spring pin into the chamfered hole of drive shaft.
CAUTION: Always use a new spring pin.
15) Install the ball joints of lower arm into knuckle arm of housing, and tighten the installing bolts.
Tightening torque: 49 Nm (5.0 kgf-m, 36 ft. lbs.)
16) Install the stabilizer link from the transverse link.
^ Except sedan turbo model
Tightening torque: 30 Nm (3.1 kgf-m, 22.1 ft. lbs.)
^ Sedan turbo model
Tightening torque: 45 Nm (4.6 kgf-m, 33.2 ft. lbs.)
17) Install the gear shift rod and stay.
1) Connect the rod to the joint.
Tightening torque: 18 Nm (1.8 kgf-m, 13.0 ft. lbs.)
2) Connect the stay to the transmission bracket.
Tightening torque: 18 Nm (1.8 kgf-m, 13.0 ft. lbs.)
18) Install the propeller shaft.
19) Install the heat shield cover. (If equipped)
20) Install the rear exhaust pipe and muffler.
21) Install the hanger bracket on the right side of transmission.
22) Install the front exhaust pipe and center exhaust pipe. (Non-turbo model)
23) Install the center exhaust pipe. (Turbo model)
24) Install the under cover.
25) Install the operating cylinder.
Tightening torque: 37 Nm (3.8 kgf-m, 27.5 ft. lbs.)
^ Non-turbo model
^ Turbo model
26) Connect the following connectors.
1) Transmission ground terminal
Tightening torque: 13 Nm (1.3 kgf-m, 9.4 ft. lbs.)
2) Vehicle speed sensor connector
3) Neutral position switch connector
4) Back-up light switch connector 27) Install the air cleaner case stay.
Tightening torque: 16 Nm (1.6 kgf-m, 11.6 ft. lbs.)
28) Install the air cleaner case and intake duct. (Non-turbo model)
29) Install the intercooler. (Turbo model)
30) Connect the battery ground terminal.
31) Take off the vehicle from lift arms.