Manual Transmission Removal
Manual Transmission AssemblyREMOVAL
1) Set the vehicle on a lift.
2) Remove the front wheels.
3) Open the front hood completely.
4) Remove the collector cover. (turbo model)
5) Remove the air intake duct.
6) Remove the 10 clips and detach the grille bracket.
7) Disconnect the ground cable from battery.
8) Remove the air intake boot assembly. (non-turbo model)
9) Remove the intercooler and the intercooler stay. (turbo model)
10) Disconnect the engine harness connector.
^ Non-turbo model
^ Turbo model
11) Disconnect the connector back-up light switch & neutral position switch.
^ Non-turbo model
^ Turbo model
12) Disconnect the transmission radio ground terminal.
^ Non-turbo model
^ Turbo model
13) Remove the throttle body. (non-turbo model)
14) Remove the starter.
15) Remove the operating cylinder from the transmission, and suspend on a wire.
16) Lift up the vehicle.
17) Remove the front under cover.
18) Drain transmission gear oil completely.
19) Remove the front, center and rear exhaust pipes. (non-turbo model)
20) Remove the center and rear exhaust pipes. (turbo model)
CAUTION:
When removing the exhaust pipes, make sure that each exhaust pipe does not drop off.
21) Remove the heat shield cover.
22) Remove the steering shaft universal joint.
23) Remove the propeller shaft.
24) Remove the MT gear shift cable and MT gear select cable from MT gear shift lever.
CAUTION:
^ Do not bend MT gear shift cable and MT gear select cable at a sharp angle.
^ Disconnect the MT gear shift cable and MT gear select cable at the MT gear shift lever side.
^ Always use new MT gear select cable if the cable is removed from selector lever COMPL of transmission side.
25) Disconnect the stabilizer link from the front arm.
26) Remove the bolt securing the ball joint of the front arm to the housing, then separate the front arms and the housing.
27) Separate the front drive shafts on both sides from the transmission.
28) Lower the vehicle.
29) Remove the engine hanger rear, and install the engine hanger rear for turbo model. (non-turbo model)
Tightening torque:
16 Nm (1.6 kgf-m, 11.8 ft-lb)
Part No. 10004AA180 Engine hanger rear
30) Remove the nuts connecting the engine mounting and the transmission main mounting bracket.
31) Set the ST on the vehicle.
CAUTION:
^ Set the chain so that it does not contact the sensors.
^ Set the arms of ST (ENGINE HANGER) at the locations shown in the figure.
ST1 99099AJ000 ENGINE HANGER
ST2 99099AJ010 CHAIN BALANCER
32) Remove the stopper rod.
33) Lift the engine slightly and remove the bolts of front cushion rubber.
34) Remove the nut and bolt of the front cushion rubber, then remove the front cushion rubber.
35) Temporarily attach ST by using two bolts.
ST 41099AJ000 SPECIAL TOOL H4
36) Lift up the engine unit high enough to install the bolt and nut to vehicle.
CAUTION:
^ Do not lift up higher than enough level to install the ST to avoid damage to the hoses and pipes inside the engine room.
^ Do not tighten the bolts and nuts excessively, or the engine mounting bracket may be deformed.
NOTE:
If it is difficult to pull out the stud bolt from transmission mounting bracket, slightly shake the engine unit while lifting up.
37) Tighten the mounting bolts on the engine side.
Tightening torque:
25 Nm (2.6 kgf-m, 18.4 ft-lb)
38) Remove the ST (ENGINE HANGER).
39) Remove the transmission main mounting bracket.
NOTE:
First, remove the transmission mounting bracket on the right side of vehicle, and then tilt the engine unit to remove the left transmission mounting bracket.
40) Remove the two mounting bolts on the upper side of the transmission.
41) Set the ST (ENGINE HANGER) again to loosen the chain sling.
42) Lift up the vehicle.
43) Place the transmission jack under the transmission.
CAUTION:
Always support the transmission case with a transmission jack.
44) Remove the bolts and nuts which hold lower side of transmission to engine.
45) Remove the front crossmember and rear crossmember from the vehicle.
46) Lower the transmission rear end (dust cover rear end).
CAUTION:
When lowering the transmission rear end, be careful not to let the converter case and steering mechanical parts contact each other.
NOTE:
Lower the transmission rear end by approx. 80 mm (3.1 in) (reference).
47) Rotate the handle of ST (ENGINE HANGER) to apply tension to the chain sling.
48) Remove the transmission assembly.
NOTE:
^ Move the transmission jack towards the rear until the main shaft is withdrawn from the clutch disc.
^ Remove it while moving the transmission jack up and down so that the engine and transmission remain directly aligned.
49) Remove the transmission cushion rubber.