Operation CHARM: Car repair manuals for everyone.

Removal and Replacement

Part 1:




Part 2:




REMOVAL AND INSTALLATION

REMOVAL SERVICE POINTS

(A) STARTER MOTOR REMOVAL
Remove the starter motor without disconnecting the starter motor harness, and secure it inside the engine compartment.

(B) TRANSAXLE MOUNT BOLT REMOVAL




Set the special tool to the vehicle and support the engine assembly.

CAUTION: Be sure to insert a piece of wood between engine hanger assembly support and front deck. Make sure that the hood weatherstrip is not caught between the front deck and the piece of wood.

(C) TIE ROD END REMOVAL




Use the special tool to disconnect the tie rod end from the knuckle.

CAUTION:
1. Be sure to tie the cord of the special tool to a nearby part.
2. Loosen the nut but do not remove it.

(D) LOWER ARM BALL JOINT REMOVAL




Use the special tool to disconnect the lower arm ball joint from the knuckle.

CAUTION:
1. Be sure to tie the cord of the special tool to a nearby part.
2. Loosen the nut but do not remove it.

(E) DRIVE SHAFT NUT REMOVAL




Use the special tool to remove the drive shaft nut from the hub.

(F) DRIVE SHAFT (RH) REMOVAL




1. Use the special tool to push out the drive shaft from the front hub.




2. Insert a pry bar to the projecting part of the drive shaft to remove the drive shaft from the transaxle.

CAUTION: Use a pry bar to remove the drive shaft from the transmission assembly, or the D.O.J. assembly will be damaged.

(G) DRIVE SHAFT AND INNER SHAFT REMOVAL




1. If the inner shaft and transaxle are tightly joined, tap the center bearing bracket lightly with a plastic hammer, etc. to remove the drive shaft and inner shaft (LH) from the transaxle.
2. Suspend the removed drive shaft and inner shaft with wire so that there are no sharp bends in any of the joints.

(H) CLUTCH RELEASE CYLINDER DISCONNECTION




Remove the clutch release cylinder and then secure at the body side without disconnecting the oil line coupling.

(I) TRANSFER ASSEMBLY REMOVAL




Cover the transfer opening with the special tool to prevent transaxle oil discharge and the entry of foreign objects.

CAUTION:
1. Be careful not to damage the transfer oil seal lip.
2. Suspend the propeller shaft not to bend it sharply.

(J) TRANSAXLE ASSEMBLY REMOVAL




Support the transaxle assembly by using a transaxle jack; then, after moving the transaxle assembly to the right, lower it.

CAUTION: Be careful not to tilt the transaxle assembly.

INSTALLATION SERVICE POINTS

(A) DRIVE SHAFT AND INNER SHAFT/DRIVE SHAFT (RH) INSTALLATION




Temporarily install the drive shaft so that the inner shaft is perpendicular to the transaxle.

CAUTION: Do not damage the oil seal lip by the serrated part of the drive shaft.

(B) DRIVE SHAFT NUT INSTALLATION




1. Be sure to install the washer and drive shaft nut in the specified direction.




2. Using the special tool, tighten the drive shaft nut.

CAUTION: Before securely tightening the drive shaft nuts, make sure there is no load on the wheel bearings.

3. If the position of the cotter pin holes does not match, tighten the nut up to 260 Nm (188 ft-lbs.) in maximum.
4. Install the cotter pin in the first matching holes and bend it securely.