MANUAL TRANSAXLE REMOVAL/INSTALLATION [A26M-R]

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L3 Turbo

1.  Disconnect the negative battery cable.

2.  Remove the battery and battery tray. (See BATTERY REMOVAL/INSTALLATION [L3 Turbo].)

3.  Remove the air cleaner component. (See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [L3 Turbo].)

4.  Remove the charge air cooler. (See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [L3 Turbo].)

5.  Remove in the fuel pump resistor. (See FUEL PUMP RESISTOR REMOVAL/INSTALLATION [L3 Turbo].)

6.  Remove the front wheels.

7.  Remove the under cover and splash shields.

8.  Remove the mudguard. (LF side)

9.  Remove the starter. (See STARTER REMOVAL/INSTALLATION [L3 Turbo].)

10.  Drain the transaxle oil into a suitable container.

11.  Remove in the order indicated in the figure.

12.  Install in the reverse order of removal.

13.  Add the specified amount of specified transaxle oil. (See TRANSAXLE OIL REPLACEMENT [A26M-R].)

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 [A26M-R].)

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1	Selector cable (See Shift Cable And Select Cable Removal Note.)
2	Shift cable (See Shift Cable And Select Cable Removal Note.)
3	Wiring harness bracket
4	Cable bracket
5	Back-up light switch connector
6	Neutral switch connector
7	Wiring harness bracket
8	Clutch release cylinder
9	Transaxle mounting bolt (upper side)
10	Tie-rod end ball joint (See FRONT CROSSMEMBER REMOVAL/INSTALLATION.)
11	Stabilizer control link
12	Lower arm ball joint
13	Drive shaft
14	Joint shaft (See JOINT SHAFT REMOVAL/INSTALLATION [ZJ, ZY, Z6, LF, L3, L3 Turbo, MZR-CD (RF Turbo)].)
15	No.1 engine mount bracket (See No.1 Engine Mount and No.4 Engine Mount Installation Note.)
16	No.1 engine mount rubber (See No.1 Engine Mount and No.4 Engine Mount Installation Note.)
17	Wiring harness bracket
18	Dynamic damper
19	Battery tray bracket
20	No.4 engine mount rubber (See No.4 Engine Mount Removal Note.) (See No.1 Engine Mount and No.4 Engine Mount Installation Note.)
21	No.4 engine mount bracket (See No.4 Engine Mount Removal Note.) (See No.1 Engine Mount and No.4 Engine Mount Installation Note.)
22	Transaxle mounting bolt (lower side)
23	Manual transaxle (See Manual Transaxle Removal Note.) (See Manual Transaxle Installation Note.)

MZR-CD (RF Turbo)

1.  Disconnect the negative battery cable.

2.  Remove the following parts:

(1)  Battery, battery tray and battery box. (See BATTERY REMOVAL/INSTALLATION [MZR-CD (RF Turbo)].)

(2)  Air cleaner component (See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [MZR-CD (RF Turbo)].)

(3)  EGR cooler. (See EGR COOLER REMOVAL/INSTALLATION [MZR-CD (RF Turbo)].)

(4)  Front wheels, tires and splash shields

(5)  Under cover

(6)  Starter (See STARTER REMOVAL/INSTALLATION [MZR-CD (RF Turbo)].)

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.

7.  Refill the engine coolant. (See ENGINE COOLANT REPLACEMENT [MZR-CD (RF Turbo)].)

Warning

•  Improperly jacking a transaxle is dangerous. It can slip off the jack and may cause serious injury.

Note

•  If the transaxle is overhauled and installed to the vehicle, perform the 'INSPECTION AFTER TRANSAXLE OVERHAUL' and verify that there is no abnormality. (See INSPECTION AFTER TRANSAXLE INSTALLATION [A26M-R].)

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1	Selector cable (See Shift Cable And Select Cable Removal Note.)
2	Shift cable (See Shift Cable And Select Cable Removal Note.)
3	Crank angle sensor connector
4	Back-up light switch connector
5	Neutral switch connector
6	Clutch release cylinder
7	Front crossmember component, steering gear and linkage component (See FRONT CROSSMEMBER REMOVAL/INSTALLATION.)
8	Drive shaft (See DRIVE SHAFT REMOVAL/INSTALLATION.)
9	Drive shaft (See DRIVE SHAFT REMOVAL/INSTALLATION.)
10	Joint shaft (See JOINT SHAFT REMOVAL/INSTALLATION [ZJ, ZY, Z6, LF, L3, L3 Turbo, MZR-CD (RF Turbo)].)
11	No.1 engine mount bracket (See No.1 Engine Mount and No.4 Engine Mount Installation Note.)
12	Transaxle mounting bolt (upper side)
13	Battery tray bracket (See No.4 Engine Mount Removal Note.) (See No.1 Engine Mount and No.4 Engine Mount Installation Note.)
14	No.4 engine mount rubber (See No.4 Engine Mount Removal Note.) (See No.1 Engine Mount and No.4 Engine Mount Installation Note.)
15	Dynamic damper (See No.1 Engine Mount and No.4 Engine Mount Installation Note.)
16	No.4 engine mount bracket (See No.4 Engine Mount Removal Note.) (See No.1 Engine Mount and No.4 Engine Mount Installation Note.)
17	Transaxle mounting bolt (lower side)
18	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.  To install the front shaft (RH) of the SST (49 C017 5A0), remove the clip shown in the figure.

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2.  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.

3.  Support the engine using the SST.

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4.  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 Installation Note

1.  Install the No.1 engine mount bracket to the transaxle.

2.  Install the No.1 engine mount rubber.

3.  Tighten the bolts B, and then temporarily tighten the bolt A and C. (L3 Turbo)

4.  Tighten the bolts B, and then temporarily tighten the bolt C. (MZR-CD (RF Turbo))

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

L3 Turbo

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MZR-CD (RF Turbo)

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6.  Install the dynamic damper. (MZR-CD (RF Turbo))

7.  Place the No.4 engine mount rubber with the body stud bolts passing through the holes and tighten the bolt as shown 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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8.  Place the battery tray bracket over the No.4 engine mount bracket with the body stud bolts passing through the holes.

9.  Place the dynamic damper over the battery tray bracket with the body stud bolts passing through the holes, then tighten the bolts and nuts in the order of D, E. (L3 Turbo)

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10.  Tighten the bolts and nuts in the order of D, E. (MZR-CD (RF Turbo))

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11.  Remove the SST (49 C017 5A0).

12.  Install the clip as shown in the figure.

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13.  Fully tighten the bolts in the order of A, C.

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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.