Supplement

The content of this article reflects the changes identified in T-SB-0352-10.

Transaxle Replacement: Removal

Parts Information






Required Tools & Equipment






NOTE: Additional SSTs may be ordered by calling 1-800-933-8335.





Repair Procedure: Removal





1. Remove the battery.

A. Loosen the nut, and separate the negative (-) battery terminal.

B. Loosen the nut, and separate the positive (+) battery terminal.

C. Loosen the nut, and remove the bolt and battery clamp.

D. Remove the battery and battery tray.





2. Remove the No. 1 engine cover sub-assembly.

A. Lift the rear of the engine cover to detach the cover from the 2 pins.

B. Lift the front of the engine cover to detach the cover from the pin and remove the engine cover.

NOTICE:
Attempting to disengage both front and rear clips at the same time may cause the cover to break.





3. Remove the inlet air cleaner assembly by removing the 2 bolts.





4. For PZEV vehicles: Remove the air cleaner cap sub-assembly.

Disconnect the vacuum hose and separate it from the air cleaner hose.

5. Remove the air cleaner cap sub-assembly (for PZEV and non PZEV).





A. Disconnect the mass air flow meter connector and separate the wire harness clamp from the air cleaner cap.





B. Disconnect the vacuum switching valve connector and 2 hoses.





C. Separate the hose from the air cleaner cap sub-assembly.





D. Loosen the hose clamp and disconnect the hose.





E. Loosen the hose clamp and disconnect the air cleaner hose.





F. Remove the 2 bolts and the air cleaner cap sub-assembly.





6. Remove the air cleaner case sub-assembly.

A. Disconnect the wire harness clamp.

B. Remove the 3 bolts and air cleaner case sub-assembly.

7. Remove the starter.





A. Disconnect the terminal 50 connector from the starter assembly.

B. Turn back the terminal cap.

C. Remove the nut and disconnect the wire harness from terminal 30.





D. Remove the 2 bolts and starter assembly.





8. Disconnect the engine wire.

A. Remove the nut and clamp.

B. Remove the 2 bolts and disconnect the 2 connectors and wire harness from the manual transaxle.





9. Disconnect the manual transmission control cable assembly.

Remove the clip and nut, and separate the transmission control cable.





10. Disconnect the No. 1 clutch hose and remove the clip.





11. Remove the upper bell housing (5) bolts.





12. Install the 2 engine hangers with the 2 bolts as shown in the illustration.

Part Number:

* No. 1 Engine Hanger: P/N 12281-36020

* No. 2 Engine Hanger: P/N 12282-36020

* Bolts: P/N 91552-81040, 91552-81025 (or equivalent)

Torque: 43 N*m (438 kgf*cm, 32 ft*lbf)

13. Install the Engine Support Bar and secure engine weight with a chain.

SST: 00002-ESUPPT-01

NOTE:
Refer to the Engine Support Bar Assembly Instructions posted on the Technical Information System (TIS), Diagnostics - Tools & Equipment - Engine Support Bar.





A. Assemble and place the main bar onto the vehicle's strut towers.

NOTICE:
* To prevent damage caused by contact between the main bar legs and body panels, apply protective tape on the strut tower before installing the main bar.

* To prevent dents in the strut tower panel, please assure that the main bar legs with 90 degree brackets are installed.





NOTE:
* Ensure that the main bar swivel is already installed on the main bar and that the main bar legs are oriented correctly (passenger side/drivers side).

* The plastic cowl cover and/or cowl may need to be removed to accommodate the bar.





B. Assemble the front bar assembly and position the legs so they can sit onto the right and left frame rails.





C. Adjust the front bar arms so they can be bolted to the upper radiator core support mounting holes.





D. Place the front bar on the vehicle with the legs sitting firmly on the right and left frame rails near the radiator support, and secure the front bar arms to the radiator core support.

NOTE:
Once in position, ensure that the hex nuts on the front bar legs are tight and the front bar is still square after installation.





E. Install the Engine Support Bar hook #2 onto the crossbar and place the crossbar assembly through the swivel on the main bar.

HINT:
The main bar swivel may be placed above or below the main bar.

NOTICE:
Be sure not to let the main bar swivel fall and damage the windshield, or damage the hood when installing the crossbar assembly.





F. Insert the straddle bar into the crossbar.

G. Adjust the height of the crossbar so it is level and insert the quick release pin through the nearest open slot in the straddle bar.





H. Attach the chain from the engine hooks to the hook #2 of the Engine Support Bar and place tension on the chain until the Engine Support Bar self centers.

CAUTION:
Ensure the Engine Support Bar is stable when fully assembled and mounted to the vehicle to ensure no damage to vehicle or technician.

14. Remove the front wheels.





15. Remove the front axle hub nut.

A. Using the SST and a hammer, release the staked part of the front axle hub nut.

SST: 09930-00010-01

NOTICE:
Loosen the staked part of the nut completely; otherwise the thread of the drive shaft may be damaged.

B. While applying the brakes, remove the front axle hub nut.

16. Remove the front wheel opening extension pad LH.

17. Remove the engine under cover LH

18. Remove the front wheel opening extension pad RH.

19. Remove the front fender apron seal LH.

20. Remove the front fender apron seal RH.





21. Separate the front suspension lower No. 1 arms.

Remove the bolt and 2 nuts, and separate the front suspension lower No. 1 arm from the lower ball joint.





22. Separate the front axle assembly.

A. Put matchmarks on the front drive shaft assembly and the axle hub.

B. Using a plastic hammer, separate the front drive shaft assembly from the front axle assembly.

NOTICE:
Be careful NOT to damage the drive shaft boot and speed sensor rotor.





23. Using the SSTs, remove the front drive shaft assembly LH.

SST: 09520-01010-02, 09520-21040-01

NOTICE:
* Be careful NOT to damage the drive shaft dust cover, boot, or oil seal.

* Be careful NOT to drop the drive shaft assembly.





24. Remove the front drive shaft assembly RH.

A. Using a screwdriver, remove the bearing bracket hole snap ring.

B. Remove the bolt and front drive shaft assembly RH from the drive shaft bearing bracket.

NOTICE:
Do NOT damage the boot or oil seal





25. Separate the front stabilizer link assembly by removing the nut.

26. Remove the front exhaust pipe assembly.





A. Disconnect the connector.





B. Remove the 2 bolts and support bracket.





C. Remove the 2 nuts and bracket.

D. Remove the 4 nuts, 2 bolts and front exhaust pipe assembly.

E. Remove the 2 gaskets from the front exhaust pipe assembly and center exhaust pipe assembly.

27. Remove the engine mounting insulator bolts and nuts from the sub-frame assembly.





A. Remove the 5 hole plugs.





B. Remove the 9 nuts, and separate the front frame assembly.





28. Remove the engine lateral control rod with the 2 nuts.

29. Remove the bolts that hold down the power steering line to the sub frame.





30. Remove the bolts that hold the power steering link assembly to the sub frame.

Remove the 2 bolts, 2 nuts, and the power steering link assembly.

NOTICE:
Because the nut has its own stopper, do NOT turn the nut. Loosen the bolt with the nut fixed.

31. Install the SST 00002-2SUPP, secondary safety support straps.

SST: 00002-2SUPP





A. Loop the strap over the frame rail rearward of the radiator support and secure the hook to the strap's floating D-ring.





B. Feed the strap over the sub-frame and under the engine in an "X" pattern.





C, Connect the strap's hook into the torque box tie-down holes. This allows the sub frame to be removed without the need to remove the support strap.

D. Ratchet the support strap until it is snugly seated on the engine and transaxle assembly.

NOTE:
Make sure that the engine moving control rod is NOT disconnected because the dog is also used as additional safety support.

32. Place a lift under the sub frame.





33. Remove the sub frame.

CAUTION:
Before removing the bolts ensure the Engine Support Bar is secure and is supporting the engine weight to ensure no damage to vehicle or technician.

A. Remove the 4 bolts, 2 nuts, and frame side rail plate RH and LH.

B. Remove the 4 bolts, 2 nuts, and front suspension member brace rear RH and LH.

34. Slowly lower the sub frame.

35. Place a transmission jack under the transmission.





36. Remove the lower (5) bell housing bolts.

37. Lower the transmission away from the vehicle.