MANUAL TRANSAXLE REMOVAL/INSTALLATION [F35M-R]

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1.  Remove the following parts:

(1)  Battery and battery tray (See BATTERY REMOVAL/INSTALLATION [ZJ, ZY, Z6].)
(2)  Air cleaner component (See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [ZJ, ZY, Z6].)
(3)  EGR pipe (ZY) (See EXHAUST SYSTEM REMOVAL/INSTALLATION [ZJ, ZY, Z6].)
(4)  Wheels, tires and splash shields
(5)  Under cover
(6)  Starter (See STARTER REMOVAL/INSTALLATION [ZJ, ZY, Z6].)

2.  Disconnect the vehicle speed sensor connector.(without ABS)

3.  Drain the transaxle oil into a suitable container.

4.  Remove in the order indicated in the table.

5.  Install in the reverse order of removal.

6.  Add the specified amount of specified transaxle oil.

Note
•  If the transaxle is overhauled and installed to the vehicle, perform the "INSPECTION AFTER TRANSAXLE INSTALLATION" and verify that there is no abnormality. (See INSPECTION AFTER TRANSAXLE INSTALLATION [F35M-R].)
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1
Back-up light switch connector
2
Neutral switch connector
3
Select cable
(See Shift Cable and Select Cable Removal Note.)
4
Shift cable
(See Shift Cable and Select Cable Removal Note.)
5
Clutch release cylinder
6
Transaxle mounting bolt (upper side)
7
Tie-rod end ball joint
(See FRONT CROSSMEMBER REMOVAL/INSTALLATION.)
8
Stabilizer control link
9
Lower arm ball joint
10
Drive shaft
(See DRIVE SHAFT REMOVAL/INSTALLATION.)
11
Joint shaft
(See JOINT SHAFT REMOVAL/INSTALLATION [ZJ, ZY, Z6, LF, L3, L3 Turbo, MZR-CD (RF Turbo)].)
12
No.1 engine mount rubber
(See No.1 Engine Mount and No.4 Engine Mount Bracket Installation Note.)
13
Battery tray bracket
14
No.4 engine mount rubber
(See No.1 Engine Mount and No.4 Engine Mount Bracket Installation Note.)
15
No.4 engine mount bracket
(See No.1 Engine Mount and No.4 Engine Mount Bracket Installation Note.)
16
Transaxle mounting bolt (lower side)
17
Manual transaxle
(See Manual Transaxle Removal Note.)
(See Manual Transaxle Installation Note.)


Shift Cable and Select Cable Removal Note

1.  Remove the both shift cable end and select cable end using a fastener remover.

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No.4 Engine Mount Removal Note

1.  Using the bolts part number 99794 1025 or M10×1.25, length 25 mm {0.98 in} to install the SST to the position shown in the figure.

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Caution
•  When attaching the SST in the engine rear side, install a suitable nut between the engine and the SST.
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Tightening torque
38—51 N·m {3.9—5.2 kgf·m, 29—37 ft·lbf}

2.  To install the front shaft (RH) of the SST (49 C017 5A0), remove the clip shown in the figure.

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3.  Install the SST using the following procedure.

Caution
•  Refer to the SST instruction manual for the basic handing procedure.
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(1)  Install the right rear shaft of the SST to the bolt of the right shock absorber as shown in the figure.
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(2)  Install the left rear shaft of the SST to the bolt of the left shock absorber (Identical position to right side).
(3)  Install front foot No.2 to the left/right front shaft of the SST, then align the groove of the front shaft of the SST with the folded up part of the vehicle as shown in the figure.
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(4)  Adjust the positions of the SST side bars so that they are the same height (left and right) and horizontal.
(5)  Make sure each joint is securely tightened.

4.  Support the engine using the SST.

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5.  Remove the battery tray bracket, No.4 engine mount rubber and bracket.


Manual Transaxle Removal Note

Warning
•  Remove the transaxle carefully, holding it steady. If the transaxle falls it could be damaged or cause injury.

1.  Adjust the SST and lean the engine toward the transaxle.

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2.  Support the transaxle on a jack.

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3.  Remove the transaxle mounting bolts.

4.  Remove the transaxle.


Manual Transaxle Installation Note

Warning
•  Install the transaxle carefully, holding it steady. If the transaxle falls it could be damaged or cause injury.

1.  Set the transaxle on a jack and lift into place.

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2.  Install the transaxle mounting bolts.

3.  Adjust the SST (49 C017 5A0) so that the engine is located at the specified position.


No.1 Engine Mount and No.4 Engine Mount Bracket Installation Note

1.  Install the No.4 engine mount bracket on the transaxle case and tighten nuts.

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2.  Install the No.1 engine mount rubber to the cross member and temporarily tighten bolts.

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3.  Place the No.4 engine mount rubber with the body stud bolts passing through the holes and tighten the bolt in the figure.

Caution
•  If the engine mount rubber installation bolt is type A, replace it with type B bolt and tighten.
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4.  Place the battery tray bracket on the No.4 engine mount rubber with body stud bolts passing through the holes and tighten bolts and nuts in the order as shown in the figure.

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5.  Remove the SSTs.

6.  Install the clip as shown in the figure.

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7.  Fully tighten the bolts.

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Caution
•  Tighten the bolts in the order shown in the figure to prevent abnormal noise and vibration after assembly.
•  Tighten the bolts while being careful of their length to prevent interference between the steering gear housing and bolt.
Bolt length (measured from below the head)
Front crossmember side: 62 mm {2.441 in}
No.1 engine mount bracket side: 65 mm {2.559 in}
Tightening torque
A type: 72.6—90.9 N·m {7.5—9.2 kgf·m, 53.6—67.0 ft·lbf}
B type: 104.2—132.6 N·m {10.7—13.5 kgf·m, 76.9—97.8 ft·lbf}