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MAINTENANCE AND REPAIR

ON-VEHICLE SERVICE


V3B15B10
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Checking Fluid Level

  1. With the vehicle on a level surface and the fluid in the transaxle cold, remove the filler plug and check the fluid level. The fluid should come to the bottom edge of the plug hole.
  2. If the level is low, add SAE 80 manual transaxle fluid through the filler plug hole until the fluid begins to run out.
  3. Reinstall the filler plug and tighten it securely.

    4. V3B15B04
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    Important : The speed gears and the synchronizer parts on this vehicle receive lubrication through specific passages in the mainshaft.

    It takes 1.8 liters (1.90 quarts) to fill the transaxle completely.

V3B15B21
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Shift Linkage Adjustment

  1. Disconnect the negative battery cable.
  2. Position the gearshift lever into NEUTRAL.

    3. Important : All the gears must be easy to engage when the vehicle is stationary, the engine is running, and the clutch is disengaged.

  3. Loosen the rod clamp bolt.

    4. V3B15B05
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  4. Remove the adjustment hole plug from the shift lever cover.
  5. Turn the gearshift rod and fully insert a 5 mm (0.2 inch) gauge pin into the adjustment hole.

    6. V3B15B06
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  6. Remove the boot from the console.
  7. Pull the boot upward to expose the shift control lever mechanism.
  8. Position the gearshift lever close to the left side of the NEUTRAL position.
  9. Insert a 5 mm (0.2 inch) gauge pin into the holes to align the gearshift lever with the gearshift lever housing.

    10. V3B15B21
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  10. Tighten the rod clamp bolt.

    11. Tighten
    Tighten the rod clamp bolt to 14 N•m (124 lb-in).


    V3B15B07
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  11. Remove the 5 mm (0.2 inch) gauge pin from the adjustment hole.
  12. Install the adjustment hole plug.
  13. Remove the 5 mm (0.2 inch) gauge pin from the gearshift lever.
  14. Install the boot to the console.
  15. Connect the negative battery cable.

V3B15B08
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Gearshift Lever

Removal Procedure

  1. Disconnect the negative battery cable.
  2. Position the gearshift lever into NEUTRAL.
  3. Disconnect the boot from the console cover.
  4. Lift the console cover upward to expose the shift control lever mechanism.

    5. V3B15B09
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  5. Rotate the gearshift lever stop clamp and remove it.
  6. Remove the gearshift lever from the gearshift lever shaft.

V3B15B09
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Installation Procedure

  1. Install the gearshift lever into the gearshift lever shaft.
  2. Install the gearshift lever stop clamp.
  3. Rotate the gearshift lever stop clamp to secure it.

    4. V3B15B07
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  4. Lower the boot and connect it to the console cover.
  5. Connect the negative battery cable.

V3B15B21
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Gearshift Tube, Boot, Bushing and/or Bearing Ring

Removal Procedure

  1. Disconnect the negative battery cable.
  2. Remove the rod clamp bolt.
  3. Separate the linkage bolt from the gearshift tube.
  4. Remove the rod clamp from the gearshift tube.

    5. V3B15B08
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  5. Position the shift lever into NEUTRAL.
  6. Disconnect the gearshift boot from the front portion of the floor console and lift upward to expose the shift control lever mechanism.

    7. V3B15B09
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  7. Rotate the gearshift lever stop clamp and remove it.
  8. Remove the gearshift lever and the boot.
  9. Remove the center console. Refer to Section 9G, Interior Trim.

    10. V3B15B11
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  10. Remove the gearshift housing bolts.
  11. Remove the gearshift tube with the gearshift housing from the vehicle.

    12. V3B15B12
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  12. Remove the gearshift tube from the gearshift housing.

    13. V3B15B13
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  13. Remove the bushing and the gearshift tube bearing from the gearshift housing.

    14. V3B15B14
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  14. Remove the bushing from the gearshift tube bearing.

V3B15B14
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Installation Procedure

  1. Install the bushing into the gearshift tube bearing.

    2. V3B15B15
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  2. Fill the grooves of the bushing with silicone grease.
  3. Press the bearing ring into the gearshift housing from the inside.

    4. V3B15B12
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  4. Install the gearshift tube through the bushing into the gearshift housing.

    5. V3B15B11
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  5. Install the gearshift housing and the gearshift tube into the vehicle.
  6. Install the gearshift housing bolts.

    7. Tighten
    Tighten the gearshift housing bolts to 8 N•m (71 lb-in).

  7. Install the center console. Refer to Section 9G, Interior Trim.

    8. V3B15B09
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  8. Install the shift lever into the shaft.
  9. Install the gearshift lever stop clamp and rotate it into position.

    10. V3B15B07
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  10. Install the gearshift boot.

    11. V3B15B21
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  11. Install the rod clamp onto the gearshift tube.
  12. Connect the linkage bolt to the gearshift tube.
  13. Install the rod clamp bolt.
  14. Adjust the shift linkage. Refer to "Shift Linkage Adjustment" in this section.
  15. Tighten the rod clamp bolt.

    16. Tighten
    Tighten the rod clamp bolt to 14 N•m (124 lb-in).

  16. Connect the negative battery cable.

V3B15B16
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Control Shift Rod

Removal Procedure

  1. Disconnect the negative battery cable.
  2. Separate the plastic clip from the end of each ball socket.

    3. V3B15B17
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  3. Separate the ball sockets from the ball studs on the linkage bolts using a pry bar.
  4. Remove the control shift rod from the vehicle.

V3B15B16
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Installation Procedure

  1. Install the control shift rod into the vehicle.
  2. Press the ball sockets onto the ball studs on the linkage bolts.

    3. V3B15B16
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  3. Connect the plastic clip on the end of each ball socket.
  4. Connect the negative battery cable.

V3B15B16
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Linkage Lever Assembly

Removal Procedure

  1. Disconnect the negative battery cable.
  2. Separate the plastic clip from the end of each ball socket.

    3. V3B15B17
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  3. Separate the ball sockets from the ball studs on the linkage bolts using a pry bar.
  4. Remove the control shift rod.

    5. V3B15B18
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  5. Remove the clip and the bolt from the universal joint.

    6. V3B15B21
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  6. Loosen the rod clamp bolt.
  7. Separate the linkage bolt from the shift tube.

    8. V3B15B20
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  8. Remove the clips.

    9. V3B15B19
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  9. Remove the linkage lever assembly from the vehicle.

V3B15B19
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Installation Procedure

  1. Install the linkage lever assembly into the vehicle.

    2. V3B15B20
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  2. Install the clips.

    3. V3B15B18
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  3. Coat the universal joint bolt with silicone grease.
  4. Install the universal joint bolt and the clip onto the universal joint.

    5. V3B15B16
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  5. Install the control shift rod.
  6. Press the ball sockets onto the ball studs on the linkage bolts.

    7. V3B15B16
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  7. Connect the plastic clips on the end of each ball socket.

    8. V3B15B21
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  8. Connect the linkage bolt to the shift tube.
  9. Adjust the shift linkage. Refer to "Shift Linkage Adjustment" in this section.
  10. Tighten the rod clamp bolt.

    11. Tighten
    Tighten the rod clamp bolt to 14 N•m (124 lb-in).

  11. Connect the negative battery cable.

V3B15B22
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Speedometer Driven Gear

Removal Procedure

  1. Disconnect the speedometer speed sensor electrical connector.

    2. V3B15B23
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  2. Remove the speedometer housing retaining bolt.

    3. V3B15B24
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  3. Remove the speedometer-driven gear and the speedometer housing.

V3B15B24
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Installation Procedure

  1. Coat the O-ring with petroleum jelly.
  2. Install the speedometer-driven gear and the speedometer housing.

    3. V3B15B23
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  3. Install the speedometer housing retaining bolt.

    4. Tighten
    Tighten the speedometer housing retaining bolt to 4 N•m (35 lb-in).


    V3B15B22
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  4. Connect the speedometer speed sensor electrical connector.

V3B15B18
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Shift Lever Cover

Removal Procedure

  1. Remove the clip and the bolt at the universal joint.

    2. V3B15B41
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  2. Remove the gearshift lever cover bolts.
  3. Separate the gearshift lever cover and the gasket from the case.

V3B15B41
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Installation Procedure

  1. Position the gearshift lever cover and the gasket onto the case.
  2. Install the gearshift lever cover bolts.

    3. Tighten
    Tighten the gearshift lever cover bolts to 22 N• m (16 lb-ft).


    V3B15B18
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  3. Install the bolt and the clip at the universal joint.
  4. Check and adjust the fluid level. Refer to "Checking Fluid Level" in this section.

V3B15B25
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Drive Axle Seal

Tools Required

KM-519 Ring Installer

Removal Procedure

    Notice : Do not damage the bearing adjusting ring with the pry bar.

  1. Remove the drive axle from the transaxle. Refer to Section 3B, Manual Transaxle Drive Axle.
  2. Remove the drive axle seal by lifting the outer lip of the seal with a pry bar.

V3B15B26
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Installation Procedure

  1. Install the new drive axle seal using the ring installer KM-519 and a hammer.
  2. Coat the seal lip with the transaxle fluid.
  3. Install the drive axle. Refer to Section 3B, Manual Transaxle Drive Axle.

V3B15B27
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Transaxle Assembly

Tools Required

DW110-060 Engine Support Fixture

Removal Procedure

  1. Disconnect the backup lamp switch electrical connector.
  2. Disconnect the speedometer speed sensor electrical connector.

    3. V3B15B18
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  3. Remove the clip and the bolt from the universal joint.

    4. V3B15B28
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  4. Remove the clutch release cylinder bracket bolts and the clutch release cylinder bracket.

    5. V3B15B29
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  5. Install the engine support fixture DW110-060.

    6. V3B15B30
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  6. Remove the transaxle-to-engine upper bolts.

    7. V3B15B31
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  7. Remove the left front transaxle mounting bracket nut.
  8. Raise and suitably support the vehicle.
  9. Remove both of the drive axle shafts. Refer to Section 3B, Manual Transaxle Drive Axle.

    10. V3B15B32
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  10. Support the transaxle with a transaxle support jack.
  11. Remove the centermember. Refer to Section 2C, Front Suspension.
  12. Remove the exhaust pipe nuts. Refer to Section 1G, Engine Exhaust.
  13. Remove the front transaxle mounting bracket bolts and nut.

    14. V3B15B33
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  14. Remove the rear transaxle mounting bracket bolts and bracket.

    15. V3B15B34
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  15. Remove the transaxle-to-engine lower bolts.

    16. V3B15B35
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  16. Slide the transaxle sideways away from the engine block.
  17. Lower the transaxle.

V3B15B35
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Installation Procedure

  1. Support the transaxle with a transaxle support jack.
  2. Install the transaxle by inserting the transaxle input shaft into the clutch disc and sliding the transaxle sideways into the engine block.

    3. V3B15B36
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  3. Install the transaxle-to-engine lower bolts.

    4. Tighten
    Tighten the transaxle-to-engine lower bolts (a) to 75 N•m (55 lb-ft).
    Tighten the transaxle-to-engine lower bolt (b) to 21 N•m (15 lb-ft).
    Tighten the transaxle-to-engine lower bolts (c) to 31 N•m (23 lb-ft).


    V3B15B37
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  4. Install the rear transaxle mounting bracket and the bolts.

    5. Tighten
    Tighten the rear transaxle mounting bracket bolts (a) to 90 N•m (66 lb-ft).
    Tighten the rear transaxle mounting bracket bolt (b) to 65 N•m (48 lb-ft).


    V3B15B38
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  5. Install the front transaxle mounting bracket bolts and the nut.

    6. Tighten
    Tighten the front transaxle mounting bracket bolts and nut to 90 N•m (66 lb-ft).


    V3B15B39
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  6. Install the exhaust pipe nuts. Refer to Section 1G, Engine Exhaust.
  7. Install the centermember. Refer to Section 2C, Front Suspension.
  8. Install the drive axles. Refer to Section 3B, Manual Transaxle Drive Axle.
  9. Install the left front transaxle mounting bracket nut.

    10. Tighten
    Tighten the nut to 155 N•m (114 lb-ft).


    V3B15B40
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  10. Install the upper transaxle-to-engine bolts.

    11. Tighten
    Tighten the transaxle-to-engine upper bolts to 75 N•m (55 lb-ft).


    V3B15B29
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  11. Remove the engine support fixture DW110-060.

    12. V3B15B28
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  12. Install the clutch release cylinder bracket and the clutch release cylinder bracket bolts.

    13. Tighten
    Tighten the clutch release cylinder bracket bolts to 75 N•m (55 lb-ft).


    V3B15B18
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  13. Install the bolt and the clip onto the universal joint.

    14. V3B15B27
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  14. Connect the speedometer speed sensor electrical connector.
  15. Connect the backup lamp switch electrical connector.
  16. Inspect the fluid level. Refer to "Checking Fluid Level" in this section.


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