Transaxle Removal and Installation
RemovalSpecial Tools Required
Engine hanger, A and Reds AART1256 or equivalent, commercially available
NOTE: Use fender covers to avoid damaging painted surfaces.
1. Disconnect the negative (-) cable first, then the positive (+) cable from the battery. Remove the battery.
2. Remove the intake air duct (A) and air cleaner housing (B).
3. Remove the battery tray.
4. Remove the engine wire harness clamp.
5. Carefully remove the slave cylinder (A) and clutch line clamp (B) so as not to bend the clutch line. Do not operate the clutch pedal once the slave cylinder has been removed.
6. Disconnect the starter cables (A), then remove the starter motor (B).
7. Disconnect the back-up light switch connectors (A).
8. Remove the transmission ground cable (B) and starter cable clamp (C).
9. First remove the cable bracket (A), then disconnect the cables (B) from the top of the transmission housing. Carefully remove both cables and the bracket together so as not to bend the cables.
10. Disconnect the Vehicle Speed Sensor (VSS) connector.
11. Remove the rear engine mount bracket brace.
12. Remove the engine wire harness (A) and two upper transmission/mounting bolts (B).
13. Remove the front engine mount bracket 3 mounting bolts.
14. Raise vehicle and make sure it is securely supported.
15. Drain transmission fluid with a shop towel covering the front and rear beams to catch any spilled fluid.
16. Remove the splash shield.
17. Remove the cotter pins (A), and loosen the castle nuts (B), then separate the ball joints and lower arms (C) on both sides (see step 3).
18. Remove the both damper forks (D).
19. Pull the driveshafts out of the intermediate shaft and differential. Coat all the precision finished surfaces with clean engine oil grease. Tie bags over the driveshaft ends.
20. Remove the intermediate shaft. Coat all the precision finished surfaces with clean engine oil grease. Tie bags over the shaft end.
21. Remove the engine stiffener.
22. Remove the radius rod mounting bolts from the lower arm (A).
23. Remove the power steering cooler line (A) from the front beam (B).
24. Make reference marks (A) on the rear beam (B) and front beam (C) then remove the front beam.
25. Lift and support the engine/transmission assembly with an engine hanger (P/N AAR-T-1256, available through the American Honda Tool and Equipment Program, or equivalent).
26. Place a floor jack under the transmission, and raise the transmission just enough to take weight off of the mounts.
27. Remove the transmission/mounting bracket (A) and transmission/mounting (B).
28. Remove the transmission/mount stud bolt (C) on the transmission housing.
29. Remove the intake manifold bracket.
30. Remove the two rear engine mount bracket (A) mounting bolts (B).
31. Remove the rear side transmission/mounting bolt (C).
32. Remove the front side transmission/mounting bolt.
33. Pull the transmission away from the engine until it clears the mainshaft, then lower it on the transmission jack. Take care not to bend the clutch line.
34. Remove the slave cylinder bracket from the transmission.
35. Remove the boot (A), the release fork (B), and the release bearing (C) from the transmission (D).
Installation
1. Check that the dowel pins are installed in the clutch housing.
2. Install the slave cylinder bracket on the transmission assembly.
3. Apply Super High Temp Urea Grease (P/N 08798-9002) to the release fork (A), the release fork bolt (B), the release bearing (C), and the release bearing guide (D) in the shaded areas.
4. Install the release bearing (C), release fork (A), and boot (E) on the transmission (F).
5. Place the transmission on the transmission jack, and raise it to the engine level.
6. Install the front side transmission/mounting bolt.
7. Install the rear side transmission/mounting bolt (A).
8. Install the 2 rear engine mount bracket (B) new mounting bolts (C).
9. Install the transmission/mount stud bolt (A) on the transmission housing.
10. Raise the transmission, install the transmission/mount (B) and transmission/mount bracket (C).
- Torque mounting bolts and nut in the sequence shown.
- Make sure the bushings are not twisted or offset.
(1) 12 x 1.25 mm 64 Nm (6.5 kgf-cm, 47 ft. lbs.)
(2) Temporary tightening
(3) 10 x 1.25 mm 38 Nm (3.9 kgf-cm, 28 ft. lbs.)
(4) 12 x 1.25 mm 54 Nm (5.5 kgf-cm, 40 ft. lbs.)
11. Remove the engine/transmission hanger.
12. Install the front beam (A) in its original position by aligning the marks (B) you made in the removal procedure.
13. Install the power steering cooler line (A) in the line clamps (B).
14. Install both radius rods (A) with new mounting bolts on the lower arm (B).
15. Install the engine stiffener.
16. Install the intake manifold bracket.
17. Install the intermediate shaft.
18. Install the driveshafts with new set rings.
19. Install the damper forks (A) with new locknuts (B).
20. Install the ball joints (C) onto the lower arms (D), and install the castle nuts (E) and cotter pins (F).
21. Install the splash shield.
22. Install the washer (A) and the front engine mount bracket mounting bolts (B).
23. Install the engine wire harness (A) and two upper transmission/mounting bolts (B).
24. Install the rear engine mount bracket brace.
25. Connect the vehicle speed sensor (VSS) connector.
26. Install the cable bracket (A) and cables (B). Turn the shift lever boot (C) so the hole is facing down.
27. Install the transmission ground cable (A) and starter cable clamp (B).
28. Connect the back-up light switch connectors (C).
29. Install the starter motor (A), then connect the starter cables (B). Make sure that the crimped side of the ring terminal is facing out.
30. Apply Super High Temp Urea Grease (P/N 08798-9002) to the end of the slave cylinder rod. Install the slave cylinder (A) and clutch line clamp (B). Take care not to bend the clutch line.
31. Install the engine wire harness clamp.
32. Install the battery bracket.
33. Install the intake air duct (A) and air cleaner housing (B).
34. Turn the breather cap so that the "F" mark points toward the front of the vehicle.
35. Install the battery. Connect the positive (+) cable first, then the negative (-) cable to the battery.
36. Refill the transmission fluid.
37. Test drive the vehicle.
38. Check the clutch operation.
39. Check the transmission for noise and smooth operation.
40. Check the front wheel alignment.
41. Loosen the three mounting bolts on the front engine mount bracket, then retorque them to 38 Nm (3.9 kgf-cm, 27 ft. lbs.). Make sure the bushings are not twisted or offset.
42. Enter the anti-theft code for the radio, then enter the customer's radio station presets.