Manual Transmission/Transaxle: Service and Repair

REMOVAL
1. Disconnect negative battery cable (first) and positive battery cable (second).
2. Remove one bolt, one nut and remove fresh air duct.
3. To remove air cleaner assembly, disconnect hose from intake manifold, MAF sensor connector, air temperature sensor connector and two bolts, one nut and then remove air cleaner assembly.
4. Disconnect back-up switch connector from connector bracket in case.
5. Disconnect vehicle speed sensor connector from right side of transaxle.
6. Disconnect ground strap (one bolt).
7. Disconnect crankshaft position sensor connector.





8. Remove one starter upper bolt.





9. Remove three clutch housing bolts.





10. Support engine with engine support bar SST (0K201 170 AA0).
11. Remove No.4 engine mounting bolts (three to transaxle) and remove No.4 engine mount.
12. Loosen four lug nuts from both front wheels (LH, RH).
13. Raise and properly support vehicle.
14. Remove both front wheels.
15. Remove both splash shields (six bolts each).
16. Remove engine mounting member (two bolts, four nuts).
17. Place drain pan under transaxle drain plug.





18. Remove transaxle drain plug and drain transaxle oil.





19. Disconnect retainer clip, set aside clutch hydraulic line and remove clutch release cylinder (two bolts).
20. Remove four No.2 engine mounting bolts and remove No.2 engine mount.
21. Remove four catalytic convener bolts (two front, two rear) and remove catalytic convener.
22. Remove three No.1 engine mount bracket bolts and loosen No.1 engine mount nut.
23. Disconnect extension bar (two washers, one nut).
24. Disconnect control rod (one nut, one bolt, one clip).
25. Remove both right and left tie rod ends from steering knuckles by removing one cotter pin and one nut each.





26. Remove both stabilizer control links by removing one nut and one bolt from each side.








27. Remove pinch bolt and both right and left ball joints and disconnect ball joints from steering knuckles.





28. Gently pry left driveshaft from transaxle and install SST(0K201 270014/K95A-4111-MT).





29. Disconnect joint shaft support mount (three bolts) from cylinder block.





30. Slide joint shaft/right driveshaft assembly out of transaxle and install SST(0K201 270 014 / K95A-41 11-MT).
31. Remove one starter lower bolt and set aside starter.
32. Remove three lower clutch housing bolts and support transaxle with jack or suitable floor jack and then remove remaining two bolts.





33. Gently separate transaxle assembly from engine and lower.





REPLACEMENT
1. Raise and suitably support vehicle.
2. Set transaxle on jack or floor jack and position transaxle under vehicle.





3. Raise transaxle and align transaxle with engine.
4. Connect transaxle to engine using five mounting bolts through clutch housing.

Tightening torque:
28-38 lb-ft (37-52 N.m, 3.8-5.3 kg-m)

5. Remove floor jack from transaxle.
6. Remove SST(0K201 2700141 K95A-41 11-MT).
7. Install starter using lower starter bolt.





8. Install new clip onto driveshaft.
9. Push driveshaft and joint shaft into transaxle with opening of clip pointing upward.
10. Install joint shaft support mount onto cylinder block with three bolts.

Tightening torque:
32-42 lb-ft (43-52 Nm, 4.4~5.3 kg-m)

11. Install left and right lower ball joints into steering knuckle then install pinch bolt.

Tightening torque:
32-45 lb-ft (43-61 N.m, 4.4-6.2 kg-m)





12. Install both right and left stabilizer control links.

Tightening torque:
32-45 lb-ft (43-61 N.m, 4.4-6.2 kg-m)

13. Install both right and left tie rod ends to steering knuckles then install tie rod end nuts.

Tightening torque:
22-33 lb-ft (30-44 N.m, 3.0-4.5 kg-m)

14. Insert cotter pins.
15. Connect control rod with one nut and two bolts.
16. Connect extension bar with two washers and one nut.
17. Install No.1 engine mount then install three mounting bolts.

Tightening torque:
49-69 lb-ft (67-93 N.m, 6.8-9.5 kg-m)

18. Install catalytic converter and four bolts (two front, two rear).

Tightening torque:
Front: 21-38 lb-ft (37-52 N.m, 3.8-5.3 kg-m)
Rear: 31-45 lb-ft (42-61 N.m, 4.3-6.2 kg-m)

19. Install No.2 engine mount, then install four mounting bolts.

Tightening torque:
28-38 lb-ft (38-51 N.m, 3.8-5.3 kg-m)





20. Install clutch release cylinder with two bolts and attach hydraulic line to retainer clip.

Tightening torque:
13-19 lb-ft (18-26 N.m, 1.9-2.6 kg-m)

21. Install drain plug.
22. Install engine mounting member-to-chassis bolts (two front) and nuts (two rear).

Tightening torque:
48-65 lb-ft (64-89 N.m, 6.5-9.1 kg-m)

23. Install two No.2 engine mount-to-mounting member nuts.

Tightening torque:
23-38 lb-ft (38-51 N.m, 3.8-5.3 kg-m)

24. Install both splash shields, then tighten six bolts.
25. Install both right and left wheels, then tighten both right and left lug nuts (four lug nuts each).

Tightening torque:
65-87 lb-ft (88-118 N.m, 9-12 kg-m)

26. Install No.4 engine mount then install mounting bolts (three to transaxle).

Tightening torque:
40-59 lb-ft (55-80 N.m, 5.6-8.2 kg-m)

27. Lower vehicle.
28. Remove engine support bar SST(0K201 170 AA0).





29. Install three clutch housing bolts.

Tightening torque:
66-86 lb-ft (89-116 N.m, 9.1-11.9 kg-m)





30. Install two starter upper bolts.

Tightening torque:
27-38 lb-ft (37-52 N.m, 3.8-5.3 kg-m)

31. Reconnect crankshaft position sensor connector.
32. Reconnect ground strap with one bolt.
33. Reconnect vehicle speed sensor connector.
34. Reconnect back-up switch connector.
35. Reinstall air cleaner assembly.
36. Reconnect air temperature sensor connector.
37. Reconnect MAF sensor connector.
38. Reinsert data link connector.
39. Reinstall fresh air duct with one bolt, one nut.
40. Reconnect positive (first) then negative (last) battery cables.
41. Add gear oil, refer to Oil Inspection.
42. Test vehicle and check fluid levels.