Removal and Replacement
Part 1:
Part 2:
Part 3:
TRANSAXLE ASSEMBLY
REMOVAL AND INSTALLATION
CAUTION: Indicates parts which should be temporarily tightened, and then fully tightened after installing the engine into the vehicle.
REMOVAL SERVICE POINTS
<> DRIVE SHAFT NUT REMOVAL
CAUTION: Do not apply pressure to the wheel bearing by the vehicle weight to avoid possible damage when the drive shaft nut is loosened.
Use special tool MB990767 (end yoke holder) to fix the hub and remove the drive shaft nut.
<> TIE ROD END CONNECTION REMOVAL
CAUTION: Do not remove the nut from ball joint. Loosen it and use the special tool to avoid possible damage to ball joint threads. Hang the special tool with cord to prevent it from falling.
1. Install special tool MB991897 (ball joint remover) as shown in the figure.
2. Turn the bolt and knob as necessary to make the jaws of special tool MB991897 (ball joint remover) parallel, tighten the bolt by hand and confirm that the jaws are still parallel.
NOTE: When adjusting the jaws in parallel, make sure the knob is in the position shown in the figure.
3. Tighten the bolt with a wrench to disconnect the tie rod end and remove the self locking nut.
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1. Use special tools MB990241 (axle shaft puller) and MB990767 (end yoke holder) <2.0L ENGINE>, MB990242 (puller shaft puller), MB990244 (puller bar), MB991354 (puller body) and MB990767 (end yoke holder) <2.4L ENGINE> to push out the drive shaft from the hub and knuckle.
2. Remove the drive shaft from the hub by pulling the bottom of the brake disc towards you, and then remove the hub retaining bolts.
CAUTION: Do not pull on the drive shaft; doing so will damage the ETJ; be sure to use the pry bar. When pulling the drive shaft out from the transaxle, be careful that the spline part of the drive shaft does not damage the oil seal.
3. Remove the drive shaft from the transaxle by the following procedure. Insert a pry bar between the transaxle case and the drive shaft, and then pry the drive shaft from the transaxle.
4. If the inner shaft is hard to remove from the transaxle, strike the bracket assembly lightly with a plastic hammer and remove the inner shaft.
5. Use special tool MB991460 (plug) to prevent the entry of foreign material into the transaxle case.
CAUTION: Do not apply pressure to the wheel bearing by the vehicle weight to avoid possible damage when the drive shaft is removed. If, however, vehicle weight must be applied to the bearing in moving the vehicle, temporarily secure the wheel bearing by using special tools MB991017 (front hub remover and installer) and MB991000 (spacer).
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Remove the starter motor with the starter motor harness still connected and secure it inside the engine compartment.
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Jack up the transaxle assembly gently with a garage jack, and then remove the transaxle mount bracket.
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CAUTION: If it is hard to turn the screwdriver (to pry off the release bearing), remove the screwdriver once and repeat the above procedure after pushing the release fork fully in direction A two to three times. Forcibly prying can cause the release bearing to be damaged.
1. Remove the cover from the service hole in the clutch housing.
2. While pushing the release fork by hand in direction A, insert a flap-tip screwdriver between the release bearing and the wedge collar.
CAUTION: Be sure to push the release fork in direction A before inserting a screwdriver.
3. Separate the release bearing from the wedge collar by prying with the screwdriver (turning the screwdriver grip 90°).
NOTE: The release fork is forced to move fully in direction B by the return spring as soon as it is separated from the wedge collar
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1.
1. Set special tool MB991895 (engine hanger) to the front fender assembling bolts (A and B) and radiator support upper insulator attaching bolts (C and D) as shown.
2. Set special tool MB991527 (hanger) and MB991454 (chain) to hold the engine/transaxle assembly.
2.
1. Assemble the engine hanger (special tool MB991928). Attach following parts to the base hanger.)
^ SLIDE BRACKET (HI)
^ JOINT (140) (MB991931)
^ FOOT (STANDARD) (MB991932)
^ JOINT (90) (MB991930)
^ FOOT (SHORT) (MB991933)
2. Set special tool MB991928 (engine hanger) to the front fender assembling bolts (A and B) and radiator support upper insulator attaching bolts (C and D) as shown.
3. Position special tool MB991527 (hanger) and MB991454 (chain) to hold the engine/transaxle assembly.
NOTE: Adjust the engine hanger balance by sliding the slide bracket (HI).
INSTALLATION SERVICE POINTS
>>A<< STABILIZER BAR INSTALLATION
Tighten the self-locking nut so that the stabilizer bar mounting bolt protrudes as shown.
Standard value (A): 22 ± 1.5 mm (0.87 ± 0.06 inch)
>>B<< TRANSAXLE MOUNT STOPPER INSTALLATION
Install the transaxle mount stopper so that the arrow points as shown in the illustration.
>>C<< DRIVE SHAFT NUT INSTALLATION
1. Be sure to install the drive shaft washer in the specified direction.
CAUTION: Before securely tightening the drive shaft nuts, make sure there is no load on the wheel bearings. Otherwise the wheel bearing will be damaged.
2. Using special tool MB990767 (end yoke holder), tighten the drive shaft nut to the specified torque.
Tightening torque: 245 ± 29 Nm (181 ± 21 ft. lbs.)