Removal and Installation

Tools Required:

- Transaxie Plugs T81P-1 177-B

- Differential Rotator T81P-4026-A

- Halfshaft Remover D83P-4026-A

- Rotunda Hi-Lift Jack 014-00210

- Rotunda Manual Transaxie Adapter 014-00225

- Rotunda Engine Support Bar 014-00750

Removal

1. Disconnect battery ground cable.






2. Wedge a wood block approximately 188mm (7 inches) in length under the clutch pedal to hold the clutch pedal up slightly beyond its normal position.

3. Remove air cleaner hose.






4. Grasp the clutch cable and pull forward, disconnecting it from the clutch release shaft assembly.

5. Disconnect the clutch cable casing from the rib on top surface of the transaxle case.

6. Install engine lifting eyes.

7. lie up wiring harness and power steering cooler hoses.

8. Disconnect speedometer cable and speed sensor wire.

9. Support engine using Engine Support Bar 014-00750 or equivalent.

10. Raise vehicle on hoist.

11. Remove wheel and tire assemblies.






12. Remove nut and bolt retaining lower control arm ball joint to the steering knuckle assembly. Discard the removed nut and bolt. Repeat procedure on the opposite side.

CAUTION: Exercise care not to damage or cut the ball joint boot. Pry bar must not contact the lower arm.






13. Using Halfshaft Remover D83P-4026-A or equivalent, pry the lower control arm away from knuckle. Repeat procedure on the opposite side.

14. Remove upper nut from stabilizer bar and separate the stabilizer from knuckle.

15. Remove tie rod nut and separate tie rod end from knuckle.

16. Disconnect heated oxygen (HO2S) sensor.

17. Remove exhaust catalyst assembly.

18. Disconnect power steering cooler from subframe and place out of the way.

19. Disconnect battery cable bracket from subframe.

CAUTION: Use care when using the pry bar for removal of the CV joint assembly, to prevent damage to the differential oil seal. Repeat procedure on the RH side.

NOTE: Lubricant will drain from the seal at this time. Install Transaxle Plugs T8 1 P-il 77-B (two required).











20. Using a large pry bar pry the LH inboard CV joint assembly from the transaxle.

NOTE: If the CV joint assembly cannot be pried from the transaxle, insert Differential Rotator T81P-4026-A through LH side and tap the joint out. Tool can be used from either side of transaxle.

Remove the inboard CV joint from the transaxle by grasping the LH steering knuckle and swinging the knuckle and halfshaft outward from the transaxle.






21. Wire the halfshaft assembly in a near level position to prevent damage to the assembly during remaining operations.

Repeat procedure on the opposite side.

22. Remove retaining bolts from center support bearing and remove RH halfshaft from transaxle.

23. Remove two steering gear retaining nuts from subframe. Support steering gear by wiring up the tie rod ends to the coil springs.

24. Remove transaxle to engine retaining bolts.






25. Remove shift mechanism stabilizer bar-to-transaxle retaining bolt. Remove shift rod-to-shift shaft retaining nut and bolt. Remove rods from transaxie.

26. Remove engine mount bolts.

27. Position jacks under body mount positions and remove four bolts, lower subframe and position out of the way.






28. Remove starter motor assembly.

29. Remove LH engine vibration dampener lower bracket.






30. Using a small screwdriver, remove the backup lamp switch connector from the transaxle backup lamp switch, located on top of the transaxle.

31. Remove backup lamp switch connector.






32. Position Rotunda Hi-Lift Jack 014-00210 and Rotunda Manual Transaxle Adapter 014-00225, or equivalent, under the transaxle.

33. Lower the transmission jack and transaxle adapter.

WARNING: THE TRANSAXLE CASE CASTING MAY HAVE SHARP EDGES. WEAR PROTECTIVE GLOVES WHEN HANDLING THE TRANSAXLE ASSEMBLY.

34. Remove the transaxle from the engine and lower it from the vehicle.

Installation

NOTE: Make sure that the transaxle assembly is flush with the rear face of the engine prior to installation of the retaining bolts.

1. Using Rotunda Hi-Lift Jack 014-00210 and Rotunda Manual Transaxie Adapter 014-00225 or equivalent, raise the transaxle into position. Engage the input shaft spline into the clutch disc and work the transaxie onto the dowel sleeves.

2. Install the engine-to-transaxle retaining bolts. Tighten to 46-63 Nm (34-46 lb-ft).

WARNING: DO NOT ATTEMPT TO START THE ENGINE PRIOR TO INSTALLING THE CV JOINTS. DIFFERENTIAL SIDE GEAR DISLOCATION DAMAGE COULD RESULT.

3. Install backup lamp switch. Tighten to 16-20 Nm (12-15 lb-ft).






4. Connect the backup lamp switch connector.






5. Install starter motor assembly retaining bolts. Tighten to 41-54 Nm (30-40 lb-ft).

6. Using jacks, position subframe and raise into position. Install four bolts and tighten to 90-115 Nm (65-85 lbft).

7. Install LH engine vibration dampener lower bracket.

8. Install engine mount bolts. Tighten to 54-75 Nm (40-55 lb-ft).

9. Connect stabilizer and shift rod to transaxle. Tighten stabilizer bolt to 47-63 Nm (35-46 lb-ft). Tighten shift rod clamp bolt and nut to 9-12 Nm (80-106 lb-in).

10. Install engine-to-transaxle bolts. Tighten to 46-63 Nm (34-46 lb-ft).

11. Install steering gear retaining nuts. Tighten to 115-135 Nm (85-100 lb-ft).

12. Install center support bearing retaining bolts. Tighten to 115-135 Nm (85-100 lb-ft).

13. Install RH halfshaft into transaxle.






14. Install LH inboard CV joint assembly into transaxle.

15. Connect battery cable bracket to subtrame.

16. Connect power steering cooler to subframe.

17. Install exhaust catalyst retaining bolts. Tighten to 34-47 Nm (25-34 lb-ft).

18. Connect heated oxygen sensor (HO2S).

19. Install tie rod in knuckle and tie rod retaining nut. Tighten to 47-64 Nm (35-47 lbft).

20. Position stabilizer bar to knuckle and install nut.






21. Install lower control arm ball joint to steering knuckle assembly. Install a new retaining nut and bolt. Tighten to 50-60 Nm (37-44 lb-ft).

22. Install wheel and tire assembly. NOTE: Apply Pipe Sealant with Teflon D8AZ- 19554-A (ESG-M4G 194-A) or equivalent to the fill plug threads, in a clockwise direction, prior to installation.






23. Check transaxle fluid level. Add specified amount of Multi-Purpose Automatic Transmission Fluid E6A7-1 9582-B (ESR-M2C163-A2) as required and install fill plug. Refer to specifications for fluid capacity and torque specifications.

24. Lower vehicle.

25. Remove Engine Support Bar 014-00750 or equivalent.






26. Using a 22mm crowfoot wrench, install speedometer cable. Connect speedometer cable and speed sensor wire.

27. Remove engine lifting eye.






28. Connect clutch cable to transaxle.

29. Install air cleaner hose.

30. Remove wood block from clutch pedal.

31. Connect battery ground cable.

32. Check transaxle for fluid leaks.