Gearbox in block with driving axle — removal

Special tool

	Axle puller 204-226 (16-092)
	Adapter for 204-226 204-226-01 (16-092-01)
	Hammer with movable striker 205-047 (15-011)
	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

Removal

1. Remove the battery tray. For more information, refer to Section 414-01.

2. Remove the air cleaner. Refer to Section 303-12 for additional information.

3. Remove the air cleaner inlet pipe. Refer to Section 303-12 for additional information.

4. Unscrew the upper bolts securing the gearbox in the block with the drive axle.



5. Remove the upper starter mounting bolts.

• Disconnect the ground cable from the transaxle.

6. Disconnect the engine wiring harness plug from the transaxle.



7.

CAUTION: If brake fluid comes into contact with the paintwork, the affected area must be immediately washed with cold water.

Disconnect the clutch slave cylinder feed line from the transaxle.

• Remove the spring loaded clamp.

8. Loosen the nuts securing the upper support of the strut assembly with the spring by four turns (on both sides).




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

10. Remove the subframe. Refer to Section 502-00 for additional information.

11. Disconnect the reversing light switch connector.



12.

CAUTION: When removing the support bracket, the catalytic converter must be supported.

Remove the catalytic converter support bracket.

• Disconnect the catalytic converter oxygen sensor from the catalytic converter.

13. Disconnect the catalytic converter from the exhaust manifold.

• Discard the gaskets and nuts as they are no longer needed.
• Disconnect the heated oxygen sensor (HO2S) from the catalytic converter.

14.

CAUTION: Excessive bending of the exhaust flexible pipe may cause damage to the flexible pipe, leading to malfunction.

Support the flexible exhaust pipe insert using a suitable tire.



15. Disconnect the flexible exhaust system connection from the exhaust pipe assembly with the muffler.

• Discard the nuts and gasket as they are no longer needed.
• Remove the catalytic converter and the flexible exhaust system connector.

16. Disconnect the gear shift cables from the transaxle.

• 1. Disconnect the shift cable and gear selector cable from the gear selector levers.
• 2. Disconnect the bracket from the gearbox in the block with the driving axle.

17.

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: Shut off the transaxle to prevent oil leakage or dirt from entering.

Disconnect the right axle shaft and intermediate shaft from the transaxle and secure them to the side.

• Allow the oil to drain into a suitable container.
• Discard the intermediate support cover and locknuts as they are no longer needed.

18.

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: Shut off the transaxle to prevent oil leakage or dirt from entering.

Using special tools, disconnect the left axle shaft from the transaxle and secure it to the side.

• Allow the oil to drain into a suitable container.
• Discard the snap ring as it is no longer needed.

19. Disconnect the vehicle speed sensor (VSS) connector.



20. Lower the vehicle.

21. Install special tools.



22. Remove the rear engine mount.

• Discard the rear support center mounting nut as it is no longer needed.

23. Using special tools, lower the engine assembly with the gearbox in the block with the drive axle.



24. Remove the rear engine support bracket mounting bolts.



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

26. Disconnect the clutch slave cylinder feed line bracket from the rear engine mount bracket.

• Remove the rear engine mount bracket.

27.

NOTE: Do not disconnect the starter plug connectors.

Disconnect the starter from the transaxle and secure it to the side.



28. Unscrew the right gearbox mounting bolts in the block with the drive axle.



29. Using suitable clamps, secure the gearbox to the drive axle block using a gearbox jack.



30. Unscrew the left bolts securing the gearbox in the block with the drive axle.



31. Remove the gearbox in block with the drive axle.