Manual transaxle — removal and installation
Removal
Note: The manufacturer requires the engine and transaxle to be removed as a unit, then separated once they are out of the vehicle.
1. Disconnect the negative cable from the battery and remove the battery (see Engine electrical systems).
2. Remove the engine and transaxle as a unit.
Caution: Do not depress the clutch pedal while the transaxle is removed from the vehicle.
Warning: Do not place any part of your body under the transaxle assembly when it’s supported only by a hoist or other lifting device.
3. With the engine and transaxle lowered, support the transaxle with a floor jack. Place a block of wood on the jack head to prevent damage to the transaxle. Safety chains will help steady the transaxle on the jack.
4. Remove the transaxle case protector fasteners and lift the case protector from the transaxle.
5. Remove the transaxle-to-engine bolts (see illustrations).
5.5a 2009 and earlier manual transaxle mounting bolts (refer to letters for torque specs when installing)
5.5b 2010 and later manual transaxle mounting bolts (refer to letters for torque specs when installing)
6. Recheck to be sure nothing is connecting the engine or the transaxle. Disconnect and label anything still remaining.
7. Move the transaxle assembly away from the engine and carefully place the transaxle assembly on the floor onto wood blocks. Leave enough room for a floor jack underneath the transaxle.
8. The clutch components can now be inspected (see Clutch and driveaxles). In most cases, new clutch components should be routinely installed whenever the transaxle is removed.
9. Check the engine and transaxle mounts and the engine control rod. If any of these components are worn or damaged, replace them.
Installation
10. If removed, install the clutch components (see Clutch and driveaxles).
11. With the transaxle secured to the jack as on removal, raise it into position and carefully slide it forward, engaging the input shaft with the clutch disc splines. Do not use excessive force to install the transaxle — if the input shaft does not slide into place, readjust the angle of the transaxle so it is level and/or turn the input shaft so the splines engage properly with the clutch.
Caution: Do NOT use transaxle- to engine bolts to force the engine and transaxle into alignment. Doing so could crack or damage major components. If you experience difficulties, have an assistant help you line up the dowel pins on the block with the transaxle. Some wiggling of the engine and/or the transaxle will probably be necessary to secure proper alignment of the two.
12. Install the transaxle-to-engine bolts and the engine-to-transaxle bolt. Tighten the bolts to the torque listed in this Chapter’s Specifications (see illustrations 5.5a and 5.5b).
13. Install the engine and transaxle unit and tighten all mounting bolts and nuts securely.
14. Reinstall the remaining components in the reverse order of removal.
15. Tighten the wheel lug nuts to the torque listed in the Tune-up and routine maintenance Specifications.
16. Add the specified amounts of coolant, oil and transaxle fluid (see Tune-up and routine maintenance).
17. Connect the negative battery cable. Start the engine and check for proper operation and leaks.
18. Shut off the engine and recheck the fluid levels. Road test the vehicle to check for proper transaxle operation and check for leakage.