Manual transaxle — removal and installation
Removal
1. Set the steering wheel straight ahead and lock the steering wheel in that position. Set the steering column tilt and telescoping to the center positions.
2. Working under the driver’s side of the instrument panel, remove the steering column coupler cover at the base of the steering column.
3. Use a piece of wire and tie the upper and lower ends of the column shaft together at the U-joints. This is to prevent the lower part of the steering shaft from sliding out of the upper end after being disconnected from the rack and pinion.
4. Loosen the pinch bolt at the lower U-joint and disconnect from the rack and pinon splines.
5. Cover the fenders and cowl using special pads. An old bedspread or blanket will also work.
6. Remove the plastic fasteners and the upper cover above the grille.
7. Remove the wiper arms, the wiper cowl and both ends (see Windshield wiper blade inspection and replacement). Remove the fasteners and the lower cowl panel from the vehicle.
8. Remove the air intake duct and the air filter housing (see Air filter housing — removal and installation). Remove the air filter housing bolts and the bracket.
9. Remove the battery and the battery tray (see Engine electrical systems).
10. Remove the PCM from the engine compartment (see Powertrain Control Module (PCM) — removal and installation).
11. Remove the clutch release cylinder and hydraulic line, without disconnecting any fittings. Support the cylinder out of the way with a length of wire or rope.
Caution: Don’t depress the clutch pedal while the release cylinder is removed.
12. Disconnect the shift cables from the shift levers at the transaxle (see Shift lever/shift cables — removal and installation).
13. Clearly label and disconnect all vacuum lines, emissions hoses, electrical connectors and wiring harness clamps/brackets that may interfere with transaxle removal. Masking tape and/or a touch up paint applicator work well for marking items. Take instant photos or sketch the locations of components and brackets.
14. Support the engine with an engine support fixture or an engine hoist (an engine support fixture is recommended, as it doesn’t have legs that extend under the vehicle that would get in the way). Connect the sling or chain to the lifting hook at the end of the engine near the transaxle, not to the lifting eye on the transaxle. If no lifting hook is provided, use the threaded hole(s) in the cylinder head to attach the sling or chain.
15. With the engine supported, remove the two upper transaxle mounting bolts.
16. Disconnect the ground strap from the transaxle mount. Remove the nuts and bolts attaching the transaxle mount and bracket and remove from the engine compartment.
17. Loosen the front wheel lug nuts, then raise the vehicle and support it securely on jack stands. Remove the wheels.
18. Remove the engine splash shield (see Intake manifold — removal and installation) and the inner fender splash shields (see Body).
19. Drain the transaxle fluid (see Tune-up and routine maintenance).
20. Remove the drive axles (see Clutch and driveline) and the intermediate shaft.
21. Remove the subframe (see Subframe — removal and installation).
22. Support the transaxle with a jack, preferably one made for this purpose. Secure the transaxle to the jack with straps or chains.
23. Remove the clutch inspection cover and the remaining transaxle-to-engine bolts.
24. Move the transaxle away from the engine to disengage the transaxle input shaft from the clutch disc, and far enough to clear the pressure plate. Lower the transaxle from the vehicle.
Note: It may be necessary to slowly lower the engine a slight amount while the jack supporting the transaxle is being lowered. This will provide more clearance between the transaxle and the body.
Installation
25. If removed, install the clutch components (see Clutch and driveline).
26. Make sure the dowel pins are installed in the engine block. With the transaxle secured to the jack with a chain, raise it into position behind the engine, then carefully slide it forward, engaging the two dowel pins on the transaxle with the corresponding holes in the block and the input shaft with the clutch plate hub splines. Do not use excessive force to install the transaxle — if the input shaft does not slide into place, readjust the angle of the transaxle so it is level and/or turn the input shaft so the splines engage properly with the clutch plate hub.
27. Install the transaxle-to-engine bolts and tighten them to the torque listed in this Chapter’s Specifications.
28. The remainder of installation is the reverse of removal, noting the following points:
- ) Refill the transaxle with the specified type of lubricant (see Manual transaxle fluid change).
- ) Tighten the drive axle/hub nuts to the torque listed in the Clutch and driveline Specifications
- ) Tighten the wheel lug nuts to the torque listed in the Tune-up and routine maintenance Specifications.
- ) Road test the vehicle for proper operation and check for leaks.