Transmission Replacement

MANUAL TRANSAXLE ASSEMBLY (MTM)








COMPONENTS

REPLACEMENT
1. PLACE FRONT WHEELS FACING STRAIGHT AHEAD
2. SEPARATE STEERING INTERMEDIATE SHAFT
3. REMOVE FRONT WHEELS
4. REMOVE ENGINE UNDER COVER LH
5. REMOVE ENGINE UNDER COVER RH
6. REMOVE EXHAUST PIPE ASSEMBLY
7. DRAIN TRANSAXLE OIL
8. REMOVE HOOD SUB-ASSEMBLY
9. REMOVE CYLINDER HEAD COVER NO.2
a. C59 T/M: Remove the 2 nuts caps, clips and No.2 cylinder head cover.
b. C60 T/M: Remove the 3 bolts, nut and No.2 cylinder head cover.
10. REMOVE AIR CLEANER ASSEMBLY
11. REMOVE BATTERY CLAMP SUB-ASSEMBLY
12. REMOVE BATTERY
13. REMOVE BATTERY TRAY





14. REMOVE BATTERY CARRIER
a. Remove the 4 bolts and battery carrier.
15. REMOVE CRUISE CONTROL ACTUATOR ASSEMBLY (W/CRUISE CONTROL)





16. DISCONNECT WIRE HARNESS
a. Disconnect the wire harness clamp.
b. Remove the 2 bolts and disconnect the 2 wire harness brackets.





c. Remove the 2 bolts and 2 ground cables.





17. DISCONNECT CONNECTOR
a. Disconnect the back-up lamp switch connector.





b. w/o ABS: Disconnect the speed sensor connector.





18. SEPARATE CLUTCH RELEASE CYLINDER ASSEMBLY
a. Remove the 5 bolts, separate the release cylinder assembly with clutch piping from the transaxle.





19. SEPARATE TRANSMISSION CONTROL CABLE ASSEMBLY
a. Remove the 2 clip, 2 washer and disconnect the cable end of the control cable assembly from the transaxle.
b. Remove the 2 clip and disconnect the control cable assembly from the bracket.





20. REMOVE STARTER ASSEMBLY
a. Remove the nut and disconnect the starter wire.
b. Disconnect the connector.
c. Remove the 2 bolts and starter assembly.
21. DISCONNECT TIE ROD END SUB-ASSEMBLY LH
SST 09628-62011
22. DISCONNECT TIE ROD END SUB-ASSEMBLY RH
SST 09628-62011
23. DISCONNECT PRESSURE FEED TUBE ASSEMBLY
SST 09023-38401
24. DISCONNECT RETURN TUBE SUB-ASSEMBLY
SST 09023-38401
25. REMOVE FRONT DRIVE SHAFT ASSEMBLY LH
SST 09520-01010, 09520-24010 (09520-32040)
26. REMOVE FRONT DRIVE SHAFT ASSEMBLY RH
SST 09520-01010, 09520-24010 (09520-32040)





27. SUSPEND ENGINE ASSEMBLY
a. Remove the 2 PCV hoses.
b. C59 T/M: Install the No.1 and No.2 engine hangers in the correct direction.
Parts No.:
No.1 engine hanger: 12281-22021
No.2 engine hanger: 12281-15040
Bolt: 91512-B1016
Torque: 38 Nm (387 kgf-cm,28 ft. lbs.)





c. C60 T/M: Install the No.1 and No.2 engine hangers in the correct direction.
Parts No.:
No.1 engine hanger: 12281-88600
No.2 engine hanger: 12282-88600
Bolt: 91512-61020
Torque: 38 Nm (387 kgf-cm,28 ft. lbs.)
d. Attach the engine chain hoist to the hangers.

CAUTION: Do not attempt to hang the engine by hooking the chain to any other part.

28. REMOVE FRONT SUSPENSION CROSSMEMBER SUB-ASSEMBLY
29. SUPPORT MANUAL TRANSAXLE ASSEMBLY
a. Support the transaxle with a transmission jack.





30. REMOVE TRANSVERSE ENGINE MOUNTING INSULATOR
a. Remove the 5 bolts, nut and engine mounting insulator LH from the body.





31. REMOVE TRANSVERSE ENGINE MOUNTING BRACKET
a. Remove the 3 bolts and engine mounting bracket LH from the transaxle.





32. REMOVE MANUAL TRANSAXLE ASSEMBLY
a. Remove the 6 bolts and transaxle from the engine.





33. REMOVE TRANSVERSE ENGINE MOUNTING BRACKET
a. Remove the bolt, nut and engine mounting insulator FR from the engine mounting bracket FR.
b. Remove the 2 bolts and engine mounting bracket FR from the transaxle.





34. REMOVE TRANSVERSE ENGINE MOUNTING BRACKET
a. Remove the bolt and engine mounting insulator RR from the engine mounting bracket RR.
b. Remove the 3 bolts and engine mounting bracket RR from the transaxle.





35. INSTALL TRANSVERSE ENGINE MOUNTING BRACKET
a. Install the engine mounting bracket RR and 3 bolts to the transaxle.
Torque: 64 Nm (653 kgf-cm, 47 ft. lbs.)
b. Install the engine mounting insulator RR and bolt to the engine mounting bracket RR.
Torque: 87 Nm (888 kgf-cm, 64 ft. lbs.)





36. INSTALL TRANSVERSE ENGINE MOUNTING BRACKET
a. Install the engine mounting bracket FR and 2 bolts to the transaxle.
Torque: 64 Nm (653 kgf-cm, 47 ft. lbs.)
b. Install the engine mounting insulator FR, bolt and nut to the engine mounting bracket FR.
Torque: 52 Nm (530 kgf-cm, 38 ft. lbs.)





37. INSTALL MANUAL TRANSAXLE ASSEMBLY
a. Align the input shaft with the clutch disc and install the transaxle to the engine.
b. Install the 6 bolts.
Torque:
Bolt A: 64 Nm (650 kgf-cm, 47 ft. lbs.)
Bolt B: 47 Nm (480 kgf-cm, 35 ft. lbs.)
Bolt C: 23 Nm (230 kgf-cm, 17 ft. lbs.)





38. INSTALL TRANSVERSE ENGINE MOUNTING BRACKET
a. Install the engine mounting bracket LH to the transaxle with the 3 bolts.
Torque: 52 Nm (530 kgf-cm, 38 ft. lbs.)





39. INSTALL TRANSVERSE ENGINE MOUNTING INSULATOR
a. Install the engine mounting insulator LH with the 5 bolts and nut.
Torque:
Bolt A: 52 Nm (530 kgf-cm, 38 ft. lbs.)
Bolt B: 80 Nm (816 kgf-cm, 59 ft. lbs.)
40. INSTALL FRONT SUSPENSION CROSSMEMBER SUB-ASSEMBLY
SST 09670-00010
41. INSTALL FRONT DRIVE SHAFT ASSEMBLY LH
42. INSTALL FRONT DRIVE SHAFT ASSEMBLY RH
43. CONNECT RETURN TUBE SUB-ASSEMBLY
SST 09023-38401
44. CONNECT PRESSURE FEED TUBE ASSEMBLY
SST 09023-38401
45. CONNECT TIE ROD END SUB-ASSEMBLY LH
46. CONNECT TIE ROD END SUB-ASSEMBLY RH





47. INSTALL STARTER ASSEMBLY
a. Install the starter assembly and 2 bolts to the transaxle.
Torque: 37 Nm (378 kgf-cm, 27 ft. lbs.)
b. Connect the starter connector.
c. Install the wire and nut to starter assembly.
Torque: 9.8 Nm (100 kgf-cm, 87 ft. lbs.)





48. CONNECT TRANSMISSION CONTROL CABLE ASSEMBLY
a. Connect the shift cable with the 2 clip from the bracket.
b. Connect the shift cable end of the shift cable with the 2 washer and 2 clip to the transaxle.





49. CONNECT CLUTCH RELEASE CYLINDER ASSEMBLY
a. Install the release cylinder with the 5 bolts.
Torque:
Bolt A: 25 Nm (250 kgf-cm, 19 ft. lbs.)
Bolt B: 12 Nm (120 kgf-cm, 9 ft. lbs.)
Bolt C: 5.0 Nm (51 kgf-cm, 44 ft. lbs.)





50. CONNECT CONNECTOR
a. Connect the back-up lamp switch connector.





b. w/o ABS: Connect the speed sensor connector.





51. CONNECT WIRE HARNESS
a. Install the 2 wire harness clamps to the transaxle with the 2 bolts.
Torque:
Bolt A: 26 Nm (260 kgf-cm, 19 ft. lbs.)
Bolt B: 13 Nm (131 kgf-cm, 9 ft. lbs.)
(1) Connect the wire harness clamp.





b. Install the 2 bolts and 2 ground cables.
Torque: 13 Nm (133 kgf-cm, 10 ft. lbs.)
52. INSTALL CRUISE CONTROL ACTUATOR ASSEMBLY (W/CRUISE CONTROL)





53. INSTALL BATTERY CARRIER
a. Install the battery carrier and 4 bolts.
Torque: 13 Nm (133 kgf-cm, 10 ft. lbs.)
54. INSTALL BATTERY TRAY
55. INSTALL BATTERY
56. INSTALL BATTERY CLAMP SUB-ASSEMBLY
Torque:
Bolt: 5.0 Nm (51 kgf-cm, 44 inch lbs.)
Nut: 3.5 Nm (36 kgf-cm, 31 inch lbs.)
57. INSTALL AIR CLEANER ASSEMBLY
Torque: 7.0 Nm (71 kgf-cm, 62 inch lbs.)
58. INSTALL CYLINDER HEAD COVER NO.2
Torque: 7.0 Nm (71 kgf-cm, 62 inch lbs.)
59. INSTALL HOOD SUB-ASSEMBLY
Torque: 13 Nm (133 kgf-cm, 10 ft. lbs.)
60. INSPECT HOOD SUB-ASSEMBLY
61. ADJUST HOOD SUB-ASSEMBLY
62. ADD TRANSAXLE OIL
63. INSPECT TRANSAXLE OIL
64. INSTALL FRONT WHEELS
Torque: 103 Nm (1,050 kgf-cm, 76 ft. lbs.)
65. INSTALL STEERING COLUMN HOLE COVER SUB-ASSEMBLY NO.1
66. CONNECT STEERING INTERMEDIATE SHAFT
67. PLACE FRONT WHEELS FACING STRAIGHT AHEAD
68. CENTER SPIRAL CABLE
69. STEERING WHEEL CENTER POINT
70. INSTALL EXHAUST PIPE ASSEMBLY
71. INSTALL ENGINE UNDER COVER LH
72. INSTALL ENGINE UNDER COVER RH
73. INSPECT FRONT WHEEL ALIGNMENT
74. CHECK ABS SPEED SENSOR SIGNAL
a. ABS WITH EBD SYSTEM
b. ABS WITH EBD & BA & TRAC & VSC SYSTEM