Removal and Installation
Remove and install the parts as shown.
TRANSAXLE REMOVAL
1. DISCONNECT NEGATIVE (-) TERMINAL CABLE FROM BATTERY
CAUTION: Work must be started after 90 seconds from the time the ignition switch is turned to the "LOCK" position and the negative (-) terminal cable is disconnected from the battery.
2. REMOVE AIR CLEANER CASE ASSEMBLY WITH AIR HOSE
3. REMOVE CRUISE CONTROL ACTUATOR
a. Remove the cruise control actuator cover.
b. Disconnect the connector.
c. Remove the 3 nuts and cruise control actuator with bracket.
4. REMOVE CLUTCH RELEASE CYLINDER AND TUBE CLAMP
5. REMOVE STARTER
a. Disconnect the connector and wire from the starter.
b. Remove the 2 bolts and starter.
6. DISCONNECT BACK-UP LIGHT SWITCH CONNECTOR
7. DISCONNECT WIRES CLAMP
8. REMOVE EARTH CABLES
9. DISCONNECT CONTROL CABLES
a. Remove the clips and washers.
b. Remove the clips from the cables.
10. REMOVE TRANSAXLE MOUNTING THREE BOLTS OF TRANSAXLE CASE UPPER SIDE
11. DISCONNECT VEHICLE SPEED SENSOR CONNECTOR
12. INSTALL ENGINE SUPPORT FIXTURE
13. TIE STEERING GEAR HOUSING TO ENGINE SUPPORT FIXTURE BY CORD OR EQUIVALENT
14. REMOVE FRONT WHEEL
15. RAISE VEHICLE
NOTE: Be sure the vehicle is securely supported.
16. REMOVE UNDER COVERS AND SIDE COVERS
17. DRAIN TRANSAXLE OIL
18. REMOVE DRIVE SHAFT Service and Repair
19. DISCONNECT STEERING GEAR HOUSING FROM FRONT SUSPENSION MEMBER
a. Remove the 4 bolts.
b. Remove the stabilizer bar bush bracket.
c. Remove the 2 set bolts and nuts.
d. Disconnect the steering gear box from the suspension member.
HINT: Suspend the steering gear box with cord.
20. REMOVE EXHAUST PIPE
a. Remove the 3 nuts.
b. Remove the 2 bolts and nuts.
c. Remove 2 bolts and exhaust pipe.
21. REMOVE STIFFENER PLATE
Remove the 3 bolts and the stiffener plate.
22. DISCONNECT ENGINE FRONT MOUNTING FROM SUSPENSION MEMBER
Remove the 2 bolts and a nut.
23. DISCONNECT ENGINE REAR MOUNTING FROM FRONT SUSPENSION MEMBER
a. Remove the 2 hole plugs.
b. Remove the 3 nut.
24. REMOVE ENGINE LEFT MOUNTING
a. Raise the transaxle and engine slightly with a jack and wooden block in between.
b. Remove the 2 hole plugs and nuts.
c. Remove the 3 bolts and engine left mounting.
25. DISCONNECT STEERING COOLER PIPE FROM SUSPENSION MEMBER
26. REMOVE FRONT SUSPENSION MEMBER
a. Remove the 2 fender liner set screws.
b. Remove the 2 bolts and 4 nuts.
c. Remove the 4 bolts.
d. Remove the 2 front lower brace, rear lower brace and front suspension member.
27. REMOVE TRANSAXLE
a. Remove the transaxle mounting bolts from the engine.
b. Lower the engine left side and remove the transaxle from the engine.
TRANSAXLE INSTALLATION
1. INSTALL TRANSAXLE TO ENGINE
Align the input shaft spline with the clutch disc and install the transaxle to the engine.
Bolt A
Torque: 64 N.m (650 kgf-cm, 47 ft-lbf)
Bolt B
Torque: 46 N.m (470 kgf-cm, 34 ft-lbf)
2. INSTALL FRONT SUSPENSION MEMBER
a. Install the front suspension member, rear lower brace, front lower brace and 4 bolts.
b. Torque the 4 bolts.
Torque: 181 N.m (1.850 kgf-cm, 134 ft-lbf)
c. Install and torque the 2 bolts and 4 nuts.
Bolt
Torque: 32 N.m (330 kgf-cm, 24 ft-lbf)
Nut
Torque: 36 N.m (370 kgf-cm, 27 ft-lbf)
d. Install the 2 fender liner set screws.
3. CONNECT STEERING COOLER PIPE TO FRONT SUSPENSION MEMBER
4. INSTALL ENGINE LEFT MOUNTING
a. Install the engine left mounting.
b. Install and torque the 3 bolts.
Torque: 52 N.m (530 kgf-cm, 38 ft-lbf)
c. Install and torque the 2 nuts.
Torque: 80 N.m (820 kgf-cm, 59 ft-lbf)
d. Install the 2 hole plugs.
5. CONNECT ENGINE REAR MOUNTING TO FRONT SUSPENSION MEMBER
a. Install and torque the 3 nuts.
Torque: 80 N.m (820 kgf-cm, 59 ft-lbf)
b. Install the 2 hole plugs.
6. CONNECT ENGINE FRONT MOUNTING TO FRONT SUSPENSION MEMBER
Install and torque the 2 bolts and a nut.
Torque: 80 N.m (820 kgf-cm, 59 ft-lbf)
7. INSTALL STIFFENER PLATE
Torque: 37 N.m (380 kgf-cm, 27 ft-lbf)
8. CONNECT STEERING GEAR HOUSING TO FRONT SUSPENSION MEMBER
a. Connect the steering gear housing to the front suspension member.
b. Install and torque the 2 set bolts and nuts.
Torque: 181 N.m (1,850 kgf-cm, 134 ft-lbf)
c. Install the stabilizer bar bush bracket.
d. Install and torque the 4 bolts.
Torque: 19 N.m (195 kgf-cm, 14 ft-lbf)
9. INSTALL DRIVE SHAFT Service and Repair
10. INSTALL EXHAUST FRONT PIPE
a. Install the exhaust front pipe.
b. Install and torque the 2 bolts and nuts.
Front side
Torque: 62 N.m (630 kgf-cm, 46 ft-lbf)
Rear side
Torque: 43 N.m (440 kgf-cm, 32 ft-lbf)
c. Connect the exhaust front pipe to the front suspension member.
d. Torque the 2 bolts.
11. FILL TRANSAXLE WITH GEAR OIL
Oil:
Gear oil super (08885-02106) or equivalent
Recommended oil
Oil grade: API GL-3, GL-4 or GL-5
Viscosity:
SAE 75 W-90
Above -18 °C (0 °F) SAE 90
Below -18 °C (0 °F) SAE 75 W
Capacity: 2.6 liters (2.7 US qts, 2.3 Imp.qts)
12. INSTALL UNDER COVERS AND SIDE COVERS
13. INSTALL FRONT WHEEL AND LOWER VEHICLE
Torque: 103 N.m (1,050 kgf-cm, 76 ft-lbf)
14. UNTIE STEERING GEAR HOUSING FROM ENGINE SUPPORT FIXTURE
15. REMOVE ENGINE SUPPORT FIXTURE
16. CONNECT VEHICLE SPEED SENSOR CONNECTOR
17. CONNECT CONTROL CABLES
a. Install the clips to the cables
b. Connect the cables to the linkage with washers and clips.
18. INSTALL EARTH CABLES
19. CONNECT WIRE HARNESS CLAMP
20. CONNECT BACK - UP LIGHT SWITCH CONNECTOR
21. INSTALL STARTER
a. Install the starter.
b. Install and torque the 2 bolts.
Torque: 39 N.m (400 kgf-cm, 29 ft-lbf)
c. Connect the connector and wire to the starter.
22. INSTALL CLUTCH RELEASE CYLINDER AND TUBE CLAMP
Torque: 13 N.m (130 kgf-cm, 9 ft-lbf)
23. INSTALL CRUISE CONTROL ACTUATOR
a. Install the cruise control actuator bracket with the 3 nuts.
b. Connect the connector.
c. Install the cruise control actuator cover.
24. INSTALL AIR CLEANER CASE ASSEMBLY WITH AIR HOSE
25. CONNECT NEGATIVE (-) TERMINAL CABLE TO BATTERY
26. INSPECT FRONT WHEEL ALIGNMENT
27. PERFORM ROAD TEST
Check for abnormal noise and smooth shifting.