Manual Transmission/Transaxle: Service and Repair

Removal
1. Remove battery and battery tray, then the air filter/air flow sensor assembly.
2. Disconnect all harnesses, cables and link rods attached to transaxle. Drain transaxle fluid.
3. On models equipped with 1.9L/4-116 DOHC engine, proceed as follows:
a. Cover condenser with cardboard and remove radiator.
b. Remove power steering pump from area without disconnecting hydraulic hoses.
c. Remove power steering pump bracket from engine compartment.

Fig. 1 Anti-sway Bar Removal:

4. On all models, remove RPM sensor, then with vehicle setting on the ground, disconnect anti-sway bar link from A Frame, Fig. 1.
5. Remove lower engine mount junction bracket, then loosen right halfshaft support bearing bolts 1/2 turn.
6. Remove lower ball joints using separator tool No. 0709 and extractor tool No. 0709 or equivalents.
7. Separate halfshafts from differential. Do not disconnect from hubs.

Fig. 2 Differential Extension Removal:

8. Remove differential extension with adjusting shim, Fig. 2.
9. Remove bellhousing inspection plate, then three starter retaining bolts.

Fig. 3 Manual Transaxle Removal:

10. Attach transaxle to hoist, Fig. 3, then remove silent block and shaft.
11. Lower transaxle assembly and tilt forward as much as possible.
12. Support engine using suitable crossbar, Fig. 3, then tighten support bolt to remove weight of engine.
13. Remove transaxle to engine retaining bolts, then lower transaxle. Prop mud shield aside.

Installation
1. Coat input shaft splines, throwout bearing guide sleeve and tips of throwout bearing forks with ``Molykote BR 2 Plus'' grease or equivalent.
2. Install new Nylstop nuts and differential side carrier seals. Pack seal ridges with suitable grease.
3. Install transaxle to engine, then tilt engine/transaxle assembly to horizontal position and remove crossbar.

Fig. 4 Silent Block Shaft Installation:

4. Install silent block shaft with limiting washer, Fig. 4, and coat with Loctite.
5. Install silent block, starter motor and differential extension with adjusting shim.
6. Install bellhousing inspection plate and connect harnesses, cables and link rods to transaxle.
7. Install RPM sensors.
8. On models equipped with 1.9L/4-116 DOHC engine, proceed as follows:
a. Install power steering pump bracket and pump.
b. Adjust belt tension on new belts to 41 ft. lbs. and used belts to 22 ft. lbs.
c. Install radiator and remove protective cardboard from condenser.
9. On all models, install air filter/air flow sensor assembly, battery tray and battery.
10. Install halfshafts into differential and tighten shaft support bearing bolts.
11. Install lower ball joints and lower engine mount junction bracket. Tighten to specifications.
12. Install exhaust header pipe, place vehicle on its wheels and connect anti-sway bar link rods.
13. Refill transaxle, if necessary and adjust clutch pedal freeplay.