Removal and Replacement

AUTOMATIC TRANSAXLE

REMOVAL

CAUTION
^ Use fender covers to prevent vehicle damage.
^ Disconnect connectors carefully to avoid damage.

NOTE
^ Mark wires or hoses for identification.

1. Remove the engine cover (A).





2. Remove the battery (A).





3. Remove the air duct (A).





4. Remove the air cleaner assembly (C) after disconnecting the air flow sensor connector (A) and loosening the clamp (B).





5. Remove the battery tray (A).





6. Disconnect the inhibitor switch connector (A), the solenoid valve connector (B) and the input shaft speed sensor connector (C).





7. Disconnect the vehicle speed sensor connector (A) and output shaft speed sensor connector (B).





8. Disconnect the transaxle oil cooler hoses (B) from the tubes by loosening the clamps (A).





9. Remove the shift cable assembly (C) by removing the nut (A) and clip (B).





10. Remove the wiring harness mounting bolts (4ea).





11. Remove the CKP sensor connector (A).





12. Disconnect the oxygen sensor connectors (B-2ea) and the power steering pressure sensor connector (A) and remove the mounting bolts (C-2ea).








13. Remove the transaxle mounting bolts (A-3ea).





14. Using the special tool(09200-38001), hold the engine and transaxle assembly safely.





15. Remove the transaxle support bracket bolts (A-4ea) and nuts (B-2ea).





16. Remove the power steering column joint bolt (A).





17. Remove the front wheels.
18. Remove the under cover (A).





19. Drain the transaxle fluid by removing the drain plug (A).





20. Drain power steering fluid through the return tube(A).





21. Disconnect the power steering pressure tube (A) from the power steering oil pump.





22. Remove the fork from the front lower arm.
23. Disconnect the lower arm, the tie rod end ball joint, the stabilizer bar link from the front knuckle.
24. Remove the front roll stopper mounting bolt (A).





25. Remove the muffler hanger rubber (A).





26. Remove the rear roll stopper mounting bolts (A-4ea) and the power steering tube mounting bolt (B).





27. Remove the mounting bolts from the sub frame by supporting the sub frame by using the special tool(09624-38000).





28. Remove the front muffler assembly (A).





29. Remove the front roll support (A) from the transaxle.





30. Remove the inner shaft bracket bolts (A-3ea).





31. Remove drive shaft (A, B) from transaxle.








32. Remove the left side cover (A).





33. Remove the starter motor mounting bolts (A) and the two bolts (B).





34. Remove the cover (A).





35. Remove the drive plate bolts (A) and the transaxle lower mounting bolts (B-6ea).





36. Lifting the vehicle up and lowering the jack slowly, remove the transaxle assembly.

INSTALLATION
Installation is in the reverse order of removal.

Perform the following :
^ Adjust the shift cable.
^ Refill the transaxle with fluid.
^ Refill the radiator with engine coolant.
^ Bleed air from the cooling system with the heater valve open.
^ Clean the battery posts and cable terminals with sandpaper, assemble them, and apply grease to prevent corrosion.

1. Using a transmission jack, install the transaxle assembly.
2. Tighten the transaxle lower mounting bolts (B-4ea, C-1ea).





3. Install the drive plate bolts (A) by turning the crankshaft.

TORQUE: 46-53 Nm (4.6-5.3 kgf.m, 33.3-38.3 lb-ft)

4. Install the cover (A).





5. Install the starter motor mounting bolts (A) and the two bolts (B).





6. Install the left side cover (A).





7. After removing the jack, insert the drive shafts (A, B).








8. Install the inner shaft bracket bolts (A-3ea).





9. Install the front roll support (A) to the transaxle.





10. Install the front muffler assembly (A).





11. Install the sub frame supported by the special tool(09624-38000).





12. Tighten the rear roll stopper mounting bolts (A-4ea) and the powersteering tube mounting bolt (B).





13. Install the muffler hanger rubber (A).





14. Tighten the front roll stopper mounting bolt (A).





15. Install the fork from the front lower arm.
16. Connect the lower arm, the tie rod end ball joint, the stabilizer bar link to the front knuckle.
17. Connect the power steering pressure tube (A) to the power steering oil pump.





18. Connect the return tube(A) with a clamp.





19. Install the under cover (A).





20. Install the front wheels and tires.
21. Install the steering column joint bolt.





22. Tighten the transaxle insulator mounting bolt (A-4ea) and nuts (B-2ea).

TORQUE: 60-80 Nm (6-8 kgf.m, 43.4-57.8 lb-ft)





23. Remove the special tool (09200-38001) holding the engine and transaxle assembly.





24. Tighten the transaxle mounting bolts (A-3ea).





25. Install the mounting bolts (C-2ea) and connect the oxygen sensor connectors (B-2ea) and the power steering pressure sensor connector (A).








26. Install the CKP sensor connector (A).





27. Install the wiring harness mounting bolts(4ea).





28. Install the shift cable assembly(C) by tightening the nut (A) and clip (B).





29. Connect the transaxle oil cooler hoses (A) to the tubes by fastening the clamps (B).





30. Install the vehicle speed sensor connector (A) and output shaft speed sensor connector (B).





31. Install the inhibitor switch connector (A), the solenoid valve connector (B) and the input shaft speed sensor connector (C).





32. Install the battery tray (A).





33. Install the air cleaner assembly (C) and connect the air flow sensor connector (A) and tightening the clamp (B).





34. Install the air duct(A).





35. Install the battery (A).





36. Refill the transaxle fluid. (refer to 'Service adjustment procedure')
37. Refill the power steering fluid and bleed the air.
38. Install the engine cover (A).