Gearbox in block with driving axle — installation

Special tool

	Engine support beam 303-290A (21-140)
	Adapter for 303-290A (21-140) 303-290-01 (21-140-01)
	Adapter for 303-290A (21-140) 303-290-02 (21-140-02)
	Adapter for 303-290A (21-140) 303-290-03 (21-140-03)

General equipment:

• Gearbox jack
• Fixing clamps

Name	Specification
Anti-seize lubricant	SAM-1C9107-A

1. Using a suitable transmission jack, install the transmission in the block with the drive axle.



2. Install the left transmission mounting bolts in the block with the drive axle.



3. Remove the transmission jack. Remove the retaining clamps.


4. Install the right transmission mounting bolts in the block with the drive axle.



5. Secure the starter to the gearbox in the block with the drive axle.



6. Install the rear engine mount bracket.

7. Connect the clutch slave cylinder feed line bracket to the rear engine mount bracket.

Install the rear engine mount bracket mounting bolts.



8. Lower the vehicle.


9. Tighten the rear engine mount bracket mounting bolts.



10. Using special tools, lift the engine assembly with the gearbox in the block with the drive axle.



11.

NOTE: Install a new rear engine mount center nut.

NOTE: Do not tighten the rear engine mount nuts at this stage.

Install the rear engine mount.



12. Remove the special tools.




13. Raise and support the vehicle. Refer to Section 100-02 for additional information.

14. Connect the vehicle speed sensor (VSS) connector.



15.

CAUTION: Support the axle shaft. The inner joint should not be deflected at an angle exceeding 18 degrees. The outer joint should not be deflected at an angle exceeding 45 degrees.

CAUTION: Do not damage the axle shaft oil seal.

CAUTION: Make sure the snap ring is installed correctly.

NOTE: Install a new snap ring.

Connect the left axle shaft to the transaxle.



16.

CAUTION: Support the axle shaft. The inner joint should not be deflected at an angle exceeding 18 degrees. The outer joint should not be deflected at an angle exceeding 45 degrees.

CAUTION: Do not damage the axle shaft oil seal.

NOTE: Install new intermediate axle bearing cap and corresponding locknuts.

Connect the right axle shaft and intermediate shaft to the transaxle.

• Install the intermediate support cover.

17. Connect the gear shift cables to the transaxle.

• 1. Connect the support bracket to the transaxle block.
• 2. Connect the shift cable and gear selector cable to the gear selector levers.

18. Apply anti-seize lubricant to the exhaust flexible connector studs.

19.

NOTE: Install a new exhaust flex joint gasket and new exhaust flex joint nuts.

Connect the flexible exhaust system connector to the exhaust pipe assembly with the muffler.



20.

NOTE: Install a new catalytic converter gasket and new catalytic converter nuts.

Connect the catalytic converter to the exhaust manifold.

• Connect the heated oxygen sensor (HO2S) to the catalytic converter.

21. Install the catalytic converter bracket.

• Connect the catalytic converter monitoring oxygen sensor to the catalytic converter.

22.

CAUTION: Do not excessively bend or twist the exhaust flexible connector. Failure to follow this instruction may result in damage to the exhaust flexible connector.

Remove the exhaust system flexible pipe support.



23. Connect the reversing light switch connector.



24. Install the subframe. Refer to Section 502-00 for additional information.

25. Lower the vehicle.

26. Tighten the nuts securing the upper strut support assembly with the spring (on both sides).



27. Connect the clutch slave cylinder feed line to the transaxle. Install the clamp.



28. Connect the engine wiring harness plug to the transaxle.



29. Install the starter mounting bolts.

• Connect the ground cable to the transaxle.

30. Install the upper transmission mounting bolts in the block with the drive axle.



31. Tighten the rear engine mount mounting nuts.



32.

NOTE: The resonator is inserted into the bracket.

Install the air filter intake resonator.



33. Install the intake manifold.



34. Connect the ground cable.



35. Install the air cleaner inlet pipe. Refer to Section 303-12 for additional information.

36. Install the air cleaner. Refer to Section 303-12 for additional information.

37. Install the battery tray. For more information, refer to Section 414-01.

38.

NOTE: The gear shift lever must be in the third and fourth gear shift channel.

Adjust the shift cables. Refer to Section 308-00 for additional information.

39. Bleed the clutch system. Refer to Section 308-00 for additional information.

40. Check the transmission fluid level and top up the transmission fluid for the manual transmission if necessary. For more information, see the chapter Draining transmission fluid from the transmission in the drive axle unit and pouring transmission fluid into the transmission in the drive axle unit available in this section.