Transmission Removal and Installation

Removal · Disconnect the negative battery terminal.

· Remove the battery and battery tray.

· Remove the bolts and the fuse box in the engine compartment, and move it aside, taking care not to stretch the wiring.

· Remove the air cleaner assembly and intake duct.

· Disconnect the switch connector.

· Remove the bolt and the transmission ground strap.

· Remove the clutch slave cylinder from the transmission housing.

· Remove the pipe bracket on the transmission and move the cylinder aside.

· Disconnect the shift cables from the transmission levers.

· Disconnect the vehicle speed sensor connector at the rear of the transmission.

· From above the transmission, remove the upper transmission-to-engine bolts and the upper starter motor bolt.

· Chock the rear wheels, raise the front of the vehicle with a jack and support it on stands. Remove the front wheels.

· Remove the lower engine undertray (if equipped). · Drain the transmission oil.

· If equipped, remove the bolts and the reinforcement plate securing the transmission to the engine.

· Remove the clutch housing cover, if equipped, by removing the bolts.

· Disconnect the muffler inlet pipe.

· Remove the drive shafts. · Attach a lifting device (electric hoist) to the engine lifting eyes and tension it so that it supports the weight of the engine.

· Remove the lower longitudinal engine mount beam as follows: - remove the two bolts and the beam protective plate; - remove the plugs and remove the three bolts securing the front engine mount to the beam; - remove the plug and remove the bolt securing the rear engine mount to the beam; - if equipped, remove the bolt and release the bracket securing the air conditioning pipe to the beam; - remove the four bolts and remove the beam; - disconnect the starter motor electrical connector.

· Remove the lower starter motor mounting bolt and remove the starter motor.

· Remove the through bolt securing the rear engine support bracket to the rubber cushion.

· Remove the three bolts securing the rear engine support bracket to the transmission case.

· Remove the nut and bolt (or two bolts on some models) and remove the left engine support strut from the mount and transmission.

· Remove the nuts and bolts and remove the left engine mount bracket from the transmission case.

· Support the transmission with a jack on a trolley and remove the lower transmission-to-engine bolts.

· Lower the engine and separate the transmission from the engine (Fig. 11.3.3), making sure the transmission does not hang on the input shaft. Lower the transmission and remove it from under the vehicle.

Fig. 11.3.3. Separating the transmission from the engine

Installation · Before installing the transmission, make sure the clutch disc is centred.

· Install in the reverse order of removal, observing the following recommendations:

tighten all fasteners to the specified torque where specified; install the drive shafts; install the exhaust pipe and muffler; fill the transmission with the oil recommended by the manufacturer.