REMOVAL & INSTALLATION
The radio may have a coded theft protection circuit. Make sure you have the code before disconnecting the battery, removing the radio fuse, or removing the radio.
- Disconnect the negative battery cable, then the positive battery cable.
- Remove the air cleaner case and the air intake tube.
- Remove the clutch pipe bracket and slave cylinder. Do not operate the clutch pedal once the slave cylinder has been removed.
- Disconnect the starter motor cables, transmission ground cable and the Vehicle Speed Sensor (VSS) connector.
- Detach the backup light switch connector and wire harness clamp.
- Remove the cotter keys and bolts securing the shift cable assembly to the shift linkage. Be sure to note that the location of the plastic washer should between the cable end and the steel washer.
Be careful not to bend or kink the cable when removing it.
- Remove the cable bracket from the clutch housing.
- Remove the four upper transaxle-to-engine mounting bolts and the lower starter mounting bolt.
- Safely raise and support the vehicle.
- Remove the front wheels.
- Drain the transaxle oil into a suitable container. Install the drain plug with a new washer.
Remove the front lower splash shield and guard bar. There are three types of fasteners securing these in place:
- The inner fender fasteners are two pieces. The inner button looking piece must be carefully pried out of the holder, then the holder can be removed.
- The guard bar and front center fasteners are attached with a 6mm bolt and are removed with a 10mm socket, on a 6 inch extension and a ratchet.
- The outer forward fasteners are Phillips head screws.
- Disconnect the heated Oxygen (O 2 S) sensor connector.
- Remove and discard the two nuts attaching exhaust pipe "A" to the hanger bracket.
- Remove and discard the nuts attaching exhaust pipe "A" to the exhaust manifold, then discard the exhaust gaskets.
- Remove and discard the nuts attaching the exhaust system to the catalytic converter, then discard the exhaust gasket. Remove exhaust pipe "A" from the vehicle.
On 4-Wheel Drive (4WD) models do the following:
- Make matchmarks on the output shaft flange and the driveshaft flange prior to removal for proper alignment when reinstalling.
- Remove the four bolts that attach the driveshaft to the transfer assembly and separate them.
- Remove the cotter pins and castle nuts from the front lower ball joints. Separate the ball joints from the lower control arms. Discard the cotter pins.
- Remove the right strut fork pinch bolt and lower through bolt and nut, then remove the strut fork from the lower control arm.
- Pry the right halfshaft out of the differential, then discard the set ring on the inner joint.
- Pry the left halfshaft out of the intermediate shaft, discard the set ring on the inner joint.
- Tie plastic bags over the halfshaft joints to keep the splines of the joints clean.
- Remove the intermediate shaft mounting bolts, and remove the intermediate shaft.
- Remove the set ring from the intermediate shaft and install a new set ring.
- Remove the rear engine stiffener.
- Remove the lower clutch housing cover.
- Remove the right front mount/bracket.
- Place a transaxle jack under the transaxle and raise it just enough to take tension off the mount, then remove the transaxle mount bracket and mount.
- Remove the rear engine mount bolts and the transaxle mounting bolts.
- While supporting the transaxle on a suitable transaxle jack, pull the transaxle away from the engine until the mainshaft is clear, and then lower the transmission.
Be careful not to bend the clutch line.
- Remove the starter motor, clutch release bearing, fork and boot.
See Figures 1 through 8
- Install the dowel pins to the clutch housing.
Apply a suitable super high temperature grease to the following components:
- The release fork bolt.
- The spline of the transaxle input shaft.
- The inside of the release bearing and the sleeve on the transaxle input shaft where the release bearing rides.
- The tips of the release fork and where the slave cylinder pin rides on the release fork.
- Install the release fork boot.
- Place the transaxle assembly on the transaxle jack and raise it to engine level.
- Install the transaxle mounting bolts and new rear mount bracket bolts. Tighten the transaxle mounting bolts to 47 ft. lbs. (64 Nm) and the rear mount bolts to 61 ft. lbs. (83 Nm).
- Raise the transaxle and install the transaxle mount. First tighten the mounting nuts and bolt to the transaxle to 47 ft. lbs. (64 Nm), then tighten the mounting through bolt to 54 ft. lbs. (74 Nm).
- Install the four upper transaxle mounting bolts and the lower starter bolt. Tighten the upper transaxle mounting bolts to 47 ft. lbs. (54 Nm), then tighten the lower starter bolt to 33 ft. lbs. (44 Nm).
- Install the right front mount/bracket. Tighten the three engine bolts to 47 ft. lbs. (64 Nm), and tighten the two frame mounting bolts to 33 ft. lbs. (44 Nm).
- Install the clutch cover. Tighten the 6x1mm bolts to 104 inch lbs. (12 Nm), tighten the 8x1.25mm bolts to 17 ft. lbs. (24 Nm). Tighten the 12x1.25mm bolt to 22 ft. lbs. (29 Nm).
- Install the rear engine stiffener. Tighten the bolt attaching the stiffener to the transaxle to 33 ft. lbs. (44 Nm). Tighten the bolts attaching the stiffener(s) to the engine to 18 ft. lbs. (24 Nm).
- Pour 1 quart (1 liter) of transmission fluid into the transaxle through the opening where the intermediate shaft is installed.
- Install the intermediate shaft with a new snap ring and tighten the bolts to 29 ft. lbs. (39 Nm).
- Remove the transaxle jack and the jackstand from the engine.
- Install new set ring to the halfshafts.
- Turn the right steering knuckle fully outward and slide the halfshaft into the differential unit until you feel the spring clip engage. Turn the left steering knuckle fully outward and slide the halfshaft onto the intermediate shaft until you feel the spring clip engage.
- Install the right strut fork. Tighten the pinch bolt to 32 ft. lbs. (43 Nm) and tighten the fork lower through bolt and nut to 47 ft. lbs. (64 Nm).
- Connect the lower ball joints to the lower control arms, tighten the castle nuts to 36-43 ft. lbs. (49-59 Nm). Install new cotter pins.
- Install exhaust pipe "A" using new gaskets and locknuts. Tighten the nuts attaching the exhaust pipe to the exhaust manifold to 40 ft. lbs. (54 Nm). Tighten the nuts attaching the exhaust system to the catalytic converter to 16 ft. lbs. (22 Nm). Tighten the exhaust pipe hanger nuts to 12 ft. lbs. (16 Nm).
- Install the engine splash shield.
- Apply a suitable super high temperature grease to the tip of the slave cylinder and install the slave cylinder to the transaxle. Tighten the mounting bolts to 16 ft. lbs. (22 Nm). Install the clutch bracket pipe and tighten the mounting bolts to 56 inch lbs. (9.8 Nm).
- Install the front wheels and lower the vehicle.
- Attach the VSS sensor and the starter motor connectors.
- Connect the transaxle ground cable and the backup light switch connector.
- Install the shift cable bracket and cable.
- Install the air cleaner housing assembly with the air intake tube.
- Refill the transaxle with the proper type and amount of lubricant.
- Connect the positive, then the negative battery cables.
- Check the operation of the clutch and smooth operation of the shifter.
- Check the front wheel alignment and road test the vehicle.
- Enter the radio security code.