Transmission Removal

Manual Transmission Assembly

REMOVAL
1) Set the vehicle on a lift.
2) Remove the front wheels.
3) Open the front hood completely.
4) Remove the collector cover.
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 of back-up light switch and neutral position switch.
^ Non-turbo model





^ Turbo model





12) Disconnect the ground cable.
^ 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 hang it with a wire or the like.





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. (nonturbo 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) Remove the stabilizer link from the front arm.
26) Remove the bolts which secure front arm ball joint to the housing, and separate the front arm and 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 and hang the engine.

CAUTION:
^ Set the ST so that the chain does not contact the sensor and other parts while hanging the engine.
^ Set the arms of ST (ENGINE HANGER) at the locations shown in the figure.

ST1 99099AJ000 SPECIAL TOOL ENGINE HANGER
ST2 99099AJ010 SPECIAL TOOL CHAIN BALANCER
GENERAL TOOL Sling chain
GENERAL TOOL Screw shackle








32) Remove the stopper rod.





33) Remove the front cushion rubbers.





34) Attach the ST with the front cushion rubber mounting bolts and nuts.

CAUTION:
Do not tighten the nuts on the engine mount excessively, or the engine mounting bracket may be deformed.

Tightening torque:
25 Nm (2.5 kgf-m, 18.4 ft-lb)

ST 41099AJ000 SPECIAL TOOL H4





35) Remove the ST (ENGINE HANGER).

NOTE:
Operation is less efficient with the ST (ENGINE HANGER) attached. Remove it temporarily.

36) Remove the transmission main mounting bracket.





37) Remove the bolts which hold upper side of transmission to engine.





38) Attach the ST (ENGINE HANGER) again.
39) Lift up the vehicle.
40) Remove the bolts and nuts which hold lower of transmission to engine.





41) Place the transmission jack under the transmission.

CAUTION:
Always support the transmission case with a transmission jack.





42) Remove the front crossmember and rear crossmember from the vehicle.





43) Remove the transmission while lowering the transmission jack.

NOTE:
Move the transmission jack towards the rear until the main shaft is withdrawn from the clutch disc.

44) Separate the transmission assembly from the transmission cushion rubber.